Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => BMW 650GS / Dakar / XChallenge Singles => Topic started by: ClimbingTurtle on January 07, 2019, 03:51:09 pm

Title: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 07, 2019, 03:51:09 pm
The Story Of The Resurrection of Blitsie….
But first lets look at who Blitsie is – or is it what Blitsie is….? Anyway,,,
Blitsie is a slightly war-torn & beaten 2007 G650 X-Challenge – used for the purpose created, ie: Adventure Riding!
Blitsie came into my position about 6 weeks ago, after I read an advert on this very fine Forum for a Gx with a shed-load of KMs on it, a heat-seized motor and the associated collateral damage that you pretty much expect from a bike that was properly used for 120,000km…. On visiting the previous owner, Blitsie was parked up under a tarp, under a carport, with the cylinder-head removed and a lotta stripped parts – not a great position to find the bike in, it always means that there will be additional work just finding out if there is gunk (or damage) hidden further down in the engine….. And, are all the parts even there…..?
Here be a few pics, but the damage is not really visible…

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC1.1_zpsxemaelaq.jpeg)

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC1.2_zpskxadq5fx.jpeg)

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC1.3_zpskngnnlhk.jpeg)


I took a few days to do a little research and also got a copy of the dealers quote to repair the damaged motor (quoted to fix heat-seized components), and checked a few sources and decided to make an offer….. Anyway, offer was declined, and I was basically told that I can either pay the asking price or the owner will strip and sell the components (she had offers on some of the parts prior to my acquisition….)  - so, I paid on a whim, a hope and a prayer and the owner very kindly delivered the broken bike, parts, papers, some spares and the instruction to keep the lightning stickers on the forks – and here he is – a little forlorn, granted…

(http://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC1.4_zpslupjskqk.jpeg)

(http://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC1.5_zpsyttjtm9r.jpeg)

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC1.6_zpspjidgtdn.jpeg)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Oubones on January 07, 2019, 04:15:13 pm
Are you going to fix the motor or replace?
For interest, is it the same as the dakar?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Black_Hawk on January 07, 2019, 04:19:27 pm
 :sip: Subscribed  :sip:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Edgar on January 07, 2019, 07:57:50 pm
Keeping an eye on this thread. It's going to be an interesting one!!! :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 07:37:50 am
Are you going to fix the motor or replace?
For interest, is it the same as the dakar?

Repair....
And its pretty much the same as the Dakar as far as I can tell - some covers differ I think, but internals are the same part numbers....

Sneak preview.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: woody1 on January 08, 2019, 07:48:05 am
If you need tools for this project I know a guy in Benoni that sells tools.  :laughing4:

Good luck  :ricky:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 07:57:17 am
If you need tools for this project I know a guy in Benoni that sells tools.  :laughing4:

Good luck  :ricky:

And if he cant find the tools - he makes his own....

Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 07:59:20 am
Anyway, I set myself a budget of R15k to get Blitsie up and running and an unrealistic time-frame of Christmas. I know its unrealistic because its after Christmas and the end is not in sight. Not even close…..

First order of business was to ascertain what we have, and by default, what we have got ourselves into! Took the X into the front garden, sprayed all the loose dirt off (covered the open holes in the motor etc.) and let it dry out some. Then I loaded it only my bike rack in my impossibly untidy garage and took a long hard look – with a pen & paper….
The obvious things are the engine and the cracked sub-frame – so I jacked the back up on a stand and rotated the rear wheel with the bike in gear and the timing chain in my hand – and the piston moved freely up & down the barrel – good news, at least its not seized!!

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/Pic%201.7_zpsg5hw6jfq.jpeg)

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/Pic%201.8%20-%20Barrel_zpsoxiudbwb.jpeg)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 08:06:12 am
The order of business then is as follows: -
-   Do an initial check of what parts are not there – there is a plastic bag full of bolts, who knows if they are all there……
-   Subframe
-   Motor – and seeing as its already partially stripped, I am going to split the casing to make sure the rest is ok, service whats not OK, and primarily, clean it of the junk, sand, cobwebs and gecko shit that accumulated in the months it stood in the elements….
-   Bearings – swingarm, steering & wheels – the time is now – may as well do them.
-   Seals – as above, as well as the water pump impellor and shaft as well as the drive gears – knowns weak parts and this is what caused the motor to be in pieces anyway
To work then!
First – lets get the sub-frame off and send it away to engineering. A BIG thanks at this time to @Halfdaft – he has been an immense help in this project and the beginning was the subframe. I started with removing the fuel tank and immediately noted that the front 2 bolts (as below) are missing – time to start with the parts list….. He is doing a great deal more, I will reflect on that later…..

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/Pic%201.9%20-%20Missing%20Bolts_zpssuh824n7.jpeg)

After getting the subframe off, stripped and delivered to Halfdaft, we decided that the original design was flawed in that the front support is a tube, sealed at the far end and welded, - to the sub-frame, meaning that the forces of general use flex the tube section, using the sealed end as the pivot and the frame as the lever – so we decided to cut the whole section off, have a solid bar turned the same diameter and bore and thread that along with the centre of the spring support to accommodate ONE long M8 Hight Tensile Cap Screw – he had this jigged up and welded in-situ to maintain the correct geometry…… Halfdaft did the turning of the alu bar, the boring and threading and the old sections were cut off in a jig to make sure the cuts were in line with each other – then it was sent out for welding….

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.0_zpsl1s7mfky.jpeg)

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.1_zpsbutfgvwx.jpeg)

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.2_zpscwakz3ei.jpeg)

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.3_zps2vn0t4cq.jpeg)

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.4_zpscpwqt3qk.jpeg)

A great success – and a great start to the project – easy if it all goes this well hey…?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 08:14:52 am
I really need an alternative to Photobucket......  >:(
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Dwerg on January 08, 2019, 08:28:29 am
I used to see this bike on my commute. Glad to see it's getting a second life  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Black_Hawk on January 08, 2019, 09:24:59 am
You are making very good progress  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Ri on January 08, 2019, 10:18:12 am
I really need an alternative to Photobucket......  >:(

Google Photos? If you have a Gmail account, you have Photos already. Just remember to share you albums, and click on each picture and copy the URL and paste between the "img" tags in your report.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: the_BOBNOB on January 08, 2019, 10:33:20 am
Nice project  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 11:47:42 am
I really need an alternative to Photobucket......  >:(

Google Photos? If you have a Gmail account, you have Photos already. Just remember to share you albums, and click on each picture and copy the URL and paste between the "img" tags in your report.

Thanks Ri - I will look into that this afternoon.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 12:50:37 pm
I really need an alternative to Photobucket......  >:(

Google Photos? If you have a Gmail account, you have Photos already. Just remember to share you albums, and click on each picture and copy the URL and paste between the "img" tags in your report.

Thanks Ri - I will look into that this afternoon.....

Nope - cant get that to work either - couldnt get Flikr to work either.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ChrisL - DUSTRIDERS on January 08, 2019, 12:55:46 pm
CT no secondhand engine to be found at ACME?

Good luck with the build. :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 01:00:37 pm
CT no secondhand engine to be found at ACME?

Good look with the build. :thumleft:

Hi Chris - never looked tbh........  :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: GazGaz on January 08, 2019, 02:19:58 pm
Love a rebuild thread :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 02:20:28 pm
Anyway, it isn’t going to be that easy apparently….
Next order of business was to get the barrel off and see what damage was done to the barrel & piston – sent some emails to Wiseco (They had no idea about what to quote), some local suppliers and then located a piston in the UK at a reasonable price (Hand luggage for my nephew) – it was easy to remove, 2 bolts and it slid off the piston – so no seizing there….!
And once cleaned, it showed surprisingly little wear – it may have been replaced at some point as there is virtually no wear on the piston, with the exception of a small burnt area on the skirt and one scratch on the barrel – but more of a mark than a scratch. Anyway, dropped it off at Halfdaft and he took it to be measured and…….
Its all in tolerance!! Yay!!!

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.5_zpsqqiolrkc.jpeg)

Now we know we don’t need a piston or a barrel, but as the motor has been exposed to the elements for a while (dust in particular) I decided to remove the motor and split the crank case to see what junk had accumulated in there, as well as do some tolerance measurements for bearings, check for wear and so on – so I ordered a new set of rings and the 4 engine gaskets. For good measure I ordered a new water pump kit, complete with bearings and drive gears…
Writing it down makes it sound so simple……
The main thing to realise is that the motor cannot come out without removing the rear swingarm support brackets – the swingarm needs to come off to remove an engine mounting bolt – perverse idea and a new form of mechanical torture had thus been invented….
First step then, is to remove the rear wheel – easy enough – and then the swingarm…. At this point the proverbial hit the proverbial…..
The right side has a large cap held on by 3 small cap screws – one of which sheared off making the removal of the cap impossible as it has to unscrew, past the sheared bolt
(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.6_zpsqbxx2q5f.jpeg)

I decided that the removal of the screw was the immediate problem, and as everything damaged had to be fixed, decided that it was the priority. Fool. You didn’t know the half of it…. So I whipped out the welder and placed a small tack on the end of the damaged bolt – the idea being that it would firstly add heat and possibly release the stuck bolt, and also give me a larger purchase area for the vice grips. But to no avail – all it did was make it nasty and scratch the cover….
PLAN B – out with mini-grinder, grind the surface flat, out with the cordless drill, centre punch the bolt and drill a 1mm pilot hole. Snap the drill, drill a 1.5mm pilot hole, snap the drill, drill a 2mm pilot hole – sense of humour remains intact, just…..
Grab the easi-outs and….

(http://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.7_zpsisjwhlyh.jpeg)

HET HOM!!!

Then I realised that the cover was still not coming out, must have stripped the threads in the from – that would be a bugger…. Of to my friends at Google for some idea of what the fork is going on and discover that there is no thread…… BUT There is a bush on the other side, that slides into a one-sided bearing as the pivot for the swingarm – and that had corroded solid and seized on…. Time to call it quits for a little while and apply The Power od Sustained Thinking….
Here it be, from the inside…..

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.8_zpslgu8e2aj.jpeg)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 02:31:16 pm
At this point i sat down and did a few hours research on non-OEM bearings for various bits on the bike - swingarm, wheel bearings, chain guides, waterpump, steering as well as the relevant seals. I approached 6 different suppliers in Jhb and the only company that was able to supply a COMPLETE order was BMG - all the seals and bearings as above for around R800..... BMW wanted closer to R4k...

Also ordered a few specialized bolts and stuff from Aut Alpina in Boksburg - Thurston  is a good contact there for parts, helped me a whole load.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Ri on January 08, 2019, 02:48:09 pm
I really need an alternative to Photobucket......  >:(

Google Photos? If you have a Gmail account, you have Photos already. Just remember to share you albums, and click on each picture and copy the URL and paste between the "img" tags in your report.

Thanks Ri - I will look into that this afternoon.....

Nope - cant get that to work either - couldnt get Flikr to work either.....

What is the challenge, exactly? Can't load photo's to Photos, can't mark the album as "shared", can't get the image to show?

You can PM me for trouble shooting, or check this or last post, if it's image URL-related: http://www.wilddog.za.net/forum/index.php?topic=1308.msg4175871#msg4175871 (http://www.wilddog.za.net/forum/index.php?topic=1308.msg4175871#msg4175871)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 08, 2019, 03:13:47 pm
I really need an alternative to Photobucket......  >:(

Google Photos? If you have a Gmail account, you have Photos already. Just remember to share you albums, and click on each picture and copy the URL and paste between the "img" tags in your report.

Thanks Ri - I will look into that this afternoon.....

Nope - cant get that to work either - couldnt get Flikr to work either.....

What is the challenge, exactly? Can't load photo's to Photos, can't mark the album as "shared", can't get the image to show?

You can PM me for trouble shooting, or check this or last post, if it's image URL-related: http://www.wilddog.za.net/forum/index.php?topic=1308.msg4175871#msg4175871 (http://www.wilddog.za.net/forum/index.php?topic=1308.msg4175871#msg4175871)

Thanks Ri - I will check the link first - but basically no pic is shown - the album is shared - I will PM you after I have played a bit more - I need to work it out myself, pig-headed apparently.....
THAT was the thread I was looking for and couldnt find!!!   :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Ri on January 08, 2019, 05:04:10 pm
Thanks Ri - I will check the link first - but basically no pic is shown - the album is shared - I will PM you after I have played a bit more - I need to work it out myself, pig-headed apparently.....
THAT was the thread I was looking for and couldnt find!!!   :thumleft:
Always glad to help :imaposer:
I know what you mean ::)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: 1ougat on January 08, 2019, 06:26:38 pm
 :sip:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: dirt rat on January 09, 2019, 07:20:59 am
Love what you are doing - these bikes are special .
Just a word of advice to the owners of X challenges - Take the trouble of removing the swingarm and greasing the bearings and bushes every 20000km.
Failing to do this will result in seized bushes as seen in this post.
From the photos in this post I can see the wiring on the fuel pump unit are not standard. Common problem on the X.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 09, 2019, 07:38:36 am
Love what you are doing - these bikes are special .
Just a word of advice to the owners of X challenges - Take the trouble of removing the swingarm and greasing the bearings and bushes every 20000km.
Failing to do this will result in seized bushes as seen in this post.
From the photos in this post I can see the wiring on the fuel pump unit are not standard. Common problem on the X.

Fuel pump wiring was glued in place with Q-Bond - I still need to deal with that....

The bike is in surprisingly good condition given the km's of hard labour it did - I believe it was the right bike for what it was used for!
It needs a shed-load of work, but the basics are still strong.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: dirt rat on January 09, 2019, 07:40:11 am
The right hand swingarm bush has a 8ml thread on the inside - lots of wd 40 and a slide hammer will eventually free it up.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: dirt rat on January 09, 2019, 07:45:43 am
If the top of the fuel pump assembly does not leak fuel and works I would leave it like that.
The alternative will involve a new assembly and a portion of the wiring loom.
Best to just put couplers on the wiring for fuel filter maintenance.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 09, 2019, 07:54:14 am
The right hand swingarm bush has a 8ml thread on the inside - lots of wd 40 and a slide hammer will eventually free it up.

Never found a thread......
Did find a angle grinder tho.....  >:D
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: dirt rat on January 09, 2019, 08:05:49 am
Look at the photo of the sheared bolt with your finger pointing at the bolt - the thread is visible in the inside centre.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 09, 2019, 09:01:10 am
Look at the photo of the sheared bolt with your finger pointing at the bolt - the thread is visible in the inside centre.

You are so right!!
I never even noticed that - but at the end of the day I cut the bush off and bought a new one, it was completely stuffed, had bearing marks all over it, so no real loss.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: dirt rat on January 09, 2019, 09:04:54 am
That would also work.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 09, 2019, 09:14:49 am
So in the meantime, we approach the issue from the left and remove that sides cap-screw/bolts/cover for the swingarm pivot – but this time I consult my mates at Google first, me being a fast learner, and see this side is indeed threaded, and extends into the engine casing, thereby centering the swingarm on the bike. Cunning. Pity this side has a collared bush that is ALSO corroded on and stuck solid. And it cant slide out, being collared…..
This is what its supposed to look like, both sides….

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%202.9_zpshqgshd8d.jpeg)

And here is the offending collar – the screwdriver is against a section that I snapped off trying to hold it with a pair of water-pump pliers – the bush is supposed to turn on the threaded shaft and stay in the swingarm when the bolt is extracted through it.

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%203.0_zpsk9yyjyzj.jpeg)

But no, its solid. And as I have damaged it already, I know I must replace it, so off to the Extreme Violence Corner for a crowbar. Obvious choice for breaking shit. No question. In minutes the collar was broken off and the mini-grinder was employed to remove the last vestiges of a collared bush…. Application of a 10mm Allen key removed the bolt, complete with seized bush through the remnants of the swingarm bearing cage….. Did I mention the bearings? They came out in pieces, what was left of them anyway. Cant help thinking he ride musta been a bit rough…..

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%203.1_zpsjf05mkkb.jpeg)

At this point I realised I could remove the right section of the frame by removing the 3 bolts holding onto the main frame/backbone and have easier access to the right stuck bolts whilst working on the bench. Cunning plan. Do it.

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%203.2_zpstirfzrjo.jpeg)

Title: Re: The Story Of The Resurrection of Blitsie….
Post by: jaybiker on January 09, 2019, 09:38:19 am
Hi, you say that you replaced the steering head bearings. Do you happen to have numbers?

Greased and reassembled mine, but they are showing all the signs at only 15,000 kays.  :(
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 09, 2019, 09:58:25 am
Hi, you say that you replaced the steering head bearings. Do you happen to have numbers?

Greased and reassembled mine, but they are showing all the signs at only 15,000 kays.  :(

Here you go - First Tab - scroll down - I will get the BMG part numbers tonight
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: buzzlightyear on January 09, 2019, 10:46:09 am
Nice thread 👌
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: woody1 on January 09, 2019, 11:44:04 am
I really enjoy these builds where things has to be made to be fixed.

I feel like something again... but not as hectic as my Bantam rebuild.. :laughing4: 

http://www.wilddog.za.net/forum/index.php?topic=155455.0
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Sandvreter on January 09, 2019, 05:06:35 pm
Love what you are doing - these bikes are special .
Just a word of advice to the owners of X challenges - Take the trouble of removing the swingarm and greasing the bearings and bushes every 20000km.
Failing to do this will result in seized bushes as seen in this post.
From the photos in this post I can see the wiring on the fuel pump unit are not standard. Common problem on the X.

As he said , grease and clean mine after any heavey trip  >:( they are notorious, and dont forget the rose joints on the rear shock, the fckrs stop swivelling and bite into the bolts holding them, next second you snap the bolt/s after grabbing some air.
Love the thread  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: noble steed on January 09, 2019, 05:18:05 pm
great thread  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Oubones on January 09, 2019, 06:56:01 pm
I really enjoy these builds where things has to be made to be fixed.

I feel like something again... but not as hectic as my Bantam rebuild.. :laughing4: 

http://www.wilddog.za.net/forum/index.php?topic=155455.0
I really enjoy seeing other people do it! :peepwall:
This year, I work ( if I have a job ), ride my bikes as much as possible ( Nam in April :thumleft:) and camp!
Not taking on no projects!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 10, 2019, 01:24:01 pm
This whole exercise was to get to this point…..

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%203.5_zpsfwubndjg.jpeg)

The engine is on the bench – pissing oil I might add, mainly because the drain plug is somewhat forked,

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%203.6.1_zpswvkx7uzr.jpeg)

So I bought a Flank-Drive socket 24mm, which spectacularly failed to loosen the offending bolt either. In the end I took the angle-grinder and cut 2 parallel sections off of the bolt, right up to the copper washer and created 2 flat surfaces for a 19mm spanner, which worked, luckily… And Auto Alpina had a sump plug in stock, with an allen drive…..
And the swimgarm bushes arrived from BMW Germany in 10 days as well – good going!!
Anyway, back to the swingarm bushes….

As seen here, the bush is seized onto the bolt holding the “blind” right side of the swingarm – and as I am replacing them, best is to take the mini-grinder with an abrasive blade and cut a slot into the bush, being careful to do as little (like none) damage to the bolt it sits on. My thought is that I am going to grease the inner bolt anyway, if there are any “nicks” on it, they will be filled with grease anyway, and the tight fit means it wont damage the new bush. Hopefully.

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%203.3_zpsk9p2xica.jpeg)

Anyway, to work it was, and the removed/cut bushes, left & right.

(https://i38.photobucket.com/albums/e136/ClimbingTurtle/X-Challenge%20Build/PIC%203.4_zpscvn6lva8.jpeg)

Lets hope we don’t regret that…..

Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 10, 2019, 01:26:22 pm
Half got Google Photo to cooperate - seems the pics are not the right size, but at least there is no script over them.....  :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 10, 2019, 01:41:39 pm
After stripping out the clutch plates (A new clutch basket will need to be procured at some point, but as its an easy fix, I didn’t order one yet) I realised that getting the basket out was going to require some innovation –@ Halfdaft stepped up to the plate once again and offered me the use of his Clutch Basket Vice Grips

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620999;image)

And which I gladly accepted and put to use.

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620927;image)

Unfortunately I should have done this with the motor in the frame as I could not budge it, without fear of breaking something, so I resumed “Sustained Thought” pose for a day or 2 – the after discussion with Halfdaft we decided that  a Pneumatic Impact Wrench, which I don’t have, was needed, so I loaded the motor in the car on a Saturday morning and took it off to Half-Daft – who fired up his compressor and completely failed to get the bolt loose – so we resorted to some good old-fashioned force and a 3-foot pipe on a heavy-duty socket drive and the Clutch Vice Grips and after a huge amount of force, managed to get it of…. The Impact Wrench took care of the nut holding the Flywheel Generator unit and a couple of other tight bolts while I was there…. And I also borrowed a specially made puller for the flywheel (its on a magnetic taper) that Halfdaft made using a laser-cut ring, threaded internal, with 3 laser-cut pulling tabs welded onto it, more shortly….

Once back at the Casa, I realized I still needed to make a plan to get the clutch basket off – so out came some flat-bar, drills, grinder and Voila!

(https://lh3.googleusercontent.com/zZFiO8O_GNU_NmYdlCoYO7jGsXAbwluyz2iUTFpFBKbHTVRxh4H-j8zQxy3oBMQGqjdPMftztiSr2l9DU4uIW74TIuRWNs4PK7NHcpp1BhZnlZb4aQ1ifeLGh471o8wHQ9LbDTq1kqXvmEJgLZsT_zsfkBT5lORlnwbmXLXelVjYJAdUXi1RElglmF9m2WwJcgrqy5G0n988rvLPAgWJVDaS3rLY-FgvxXTAYkMaDD2AYEVpcBq3cYlHFwNSCClqAuh41RzJWrfUPgPocqWg_3aJ7_2IuZyFBCtbqlox_fa-x53CP9AWkyA08JxfJY22T9KZEB7THsvOdWHE9UnUcyn8IF1VUx0BZJw23kyjz-NAFCIZLm39k4F6LlOcC_Y12wDjDhR-maxUDSmtvZ9hl4IO_ZVS6471gqYGVl6dtVfEhBtqSB4uiCkdnI9klN4tx-AfMrLlUBKaCHGCicF8JllfJR6FWjm-iv5h0ic0u_2zAH8QVMHByIW0hU-xTd97Dy0fd0EOG79ALI-s-w-reLK_3cJkzvh1YwYHS9PBzGg5-Gp4bUYDpUGRZpOTknGScCkn669RAAmUkPA04QejHBO0jqcvfWqVuk4pDTBBWzz31wNrTbBrNDXmtI_ynOUZxEed0CMDuMzWFejWY0U8jfW4L4H9ixALQ5OhZbayUsFXKpte7IzJESc2DBYbz5hN1vDphVc6b7NAShLEwA=w470-h626-no)

(https://lh3.googleusercontent.com/0GHyZDvCYW8jTjtMIT7TXFv_piwKr-9m8GxnMQoPygTyYg7rMdyHIB6IUbaR08VEwd3ngkTvjhmVHQ4q4zxJATY9EjMSHDJ8O3ZEcdbR5rcJVqdKKMcgRugGq0CcPp9HJwMGf8BvEHhRLEPCDpkDpmXY5n101ttIBhLnGXFMKp6N7VGy-r2Pp46qpWaVBTZfMLpfRIuJKjw4CCgTpCMC6xsuprXuvelpUrcq8f6I86tHG7OiC8Kw5UdykZSXn3-u2kXiuykBW2Jsw8rPSfqefPoILuHRjzuKJM_HybfHElQAG6C86Ugmzbqja33hQKnJd-ASL_9hbJn8kftnhu12LnSvRWZSqeHHLJy9TIu2ExyV6WjCLTMwwR3ggsSLjzsdeBjagLEFmfVVs-98DeYthnuF_Uy4omtKwU80_mFY3nPkZ6ntdWsfhqKU15yqw4jmgTBk9F1G4SMpePwTtsFDLXUCKjDLuRjObH5cCN93uYXUKCPG1sWoRd0CwIs3qGumhB8-IdZqu2DzNF6OeE7SkX-6OL9EdukEP_oU_VQA6enr0kwTMg42HxUpFjym5AoiK8JnikxDwHQw1eqVEaFO2My_mLYkF0eOTwNeI5Poi15eFtK8te3btnG14X0L-00mtkDisaM1OmtfvachDM6kEw3lfUSWGKqizZSWqY8smaQe0x0PNGp57oqnNeatuscszX1idVjWkHwIV8aQ4w=w470-h626-no)

Next task is to remove the flywheel – a task made easy by the afore-mentioned special tool made by Half-daft – its brilliant, and this was the 2nd time it has ever been used….

(https://lh3.googleusercontent.com/b3CaM8EaULoRpdthQloBsqJCiTJCM_5UPl44hA6v45OceWxud_TKn2X_u0J5jwPK5igJrpu55cCcMKeb1hDQDFLJaT7gnF4za8EdqfxTk3Mf9RXejt-u2LdzzMBqlij_t4OxvYPw6UJc3goszTBykRelsCa6TAtsi0bU645kipOSffoB0uRYDMvsL37wJo4nfL_A2dr21Jle6bs8Bry783hgT0CMoMNjw2DEqwJPT3vGVncaGYXWezCmvCozSn0hnR2e4BU6bmAnxS3IXWtxxn9lyd6otiQg8ScrwoweeHC8o7CiXkNzYsSwtWbELGniFWowVEAeUpS6ke26yrXe5qZuUX5XnkQny_zy0rgmI_W9zwXKUJcp3cztPD3_a0uZJDnHTxPbR7wg_WNZVvTsjqMvEfaI2XoQaJel_1UP0WoRDMW8q1lgsXO40JITK3L1ME-aOyDccJTKCAcgtQkyxJ3uHuZI-IWWsGnhwFAqWmEdnd-hMFopg_o-dpuJP-TlrM2zPu5ufOZpDZsUIqWcd-Aok7n5XYChfjpGuCrTby4Pregkd3r7e_FAXIuxx9mmu8mtBH-eGM-QA-NkagBzcWVUi5G8pnXzxGW0CNDUqeMTvt363Z-Ee72wIGPEUcG2fqwSIxXXe7uJ5VOctuuBS_toDNXtp7tKoqVGf_9qYZQBG1hmjbFmxfFHFDy5Wo-js6fAAfZF1Zws9RkRcw=w835-h626-no)

(https://lh3.googleusercontent.com/IpINkOFOl6-49vbvSfHyAO54ixyP4g3FfbY2FK6T_EWkdOaK_ugXf32VHqB9ArshwNI0Pw1l1db9sGrGi_68lGl0M8Ydg-hVrYSoQLoGW3ZLEmBjznK_MzzPNQuGxToTG1xyhg-J59nj2aEOQd2PLCGh6tMj_ZnoHBf2dnu_3HXEhFvGysAzaFGO8SH-HpYzKlNTMRsL4OVZbCn9QEiSOO29DzzXQMR9s0z5VofkIvEftNs5ODh9ndkg2JEStDFBYkHT1rN59-kkhylFYMDCcU9ZSCn6mt8-t3gRE9zTbNMdceMRhvlRv4Xt8vfUS8Eubs-gIbpsebffQjb_zWSAgDZbyZawGRXDb5XmGGAplAR_QLGV5tQ2Nd5DgFVKNAKYwJ08-SjSbpKiHJoALd3cFY2KC0hkYthnTX9seT5Zf-855cDo4KA2jDbX6XBAoCA1rZrL7FwPBCVuke4BNrQfZcFoA1WOGqumdRtV3lfGou2P0MtvdY8DyvDzPWhx4nJZRdnAC-pyWL7XnZFBwYcz_asC9_v02e9n87K0UvS2Q0p5kk3EJOv2wDSY0ukbZi57Uni5MIH0Q2tEkp6qdW5zO5oM8Fy31CwMhP-a2pz6a0WRsbF27iusa5_JFGjs1fYbepIqMF4snzNQKlTocgMcl8kNeyEsBidtNPIZ1Ykgdfu2X3PaUqHAPERfBmZ6JokT7kOYPub4nRM5qmHa3Q=w470-h626-no)

(https://lh3.googleusercontent.com/qpV4RFQwZEChRV77FRrLDjARZ067lMiD5f3VL0Tq6RISoCLYNi5d26qexeb53n0M_rNMdn-j-pEIyQuFse9mNLzFJ38FV4rD0Wvhukt-NBzqVdZOKChLRkER5Tt7sQ-ds3B5xrW9HE98B5Ga0BzT9s6lAQwRE8Rw_STVFriOn03U8LONhmf-2-J3YWuWs8M8nfprteZMjGn81ZjBv3TCbgz_Szzyd4ia1QVUaxQ1zZ22_FGh4Rr1pd7E-CJgRX3uSY8XmPZLI1Hea2mRQ2VpzfLqZQEg2jEieMbyGZ7inmzIORVeeuYXpvrhA1ENpiAe0kyjuHqQ9gQIsHzcTolOKxkgAlbo-bA_mV3Eiv46RlNhjxtoYx6hggQEjZXwgH1tTkfw8An0lJ_rRvrgRKqmEDybFTSgYdAS1WvDOt-5IlyrB8Q9FcFHxF8zQyOp_V4LfarkwY8twEC7-EwVUhNWcvOdx2dr7JXma1tGfYHuKwuwJU8HF33LweMpBJXmM63AGtAOwJQG4kbVpioOoKj5xXI3RG9qJ0V-fyQoPhaGrEC9RXYEMCiXMnpA7etOOE6PAnJu8O0aBVtVGSw3fNPtba06pXcvgLy2MV_j-LJd7dVipY-MODXZdPA-fQdbqTaK4N85_D-BeE70CTUR94YZsWKVzxLpX59gDclzh9EyQhKoyskiG97xx4giXekVr0EtgjPZsf2ct6TS4yRrxw=w470-h626-no)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Ri on January 10, 2019, 01:58:51 pm
Half got Google Photo to cooperate - seems the pics are not the right size, but at least there is no script over them.....  :biggrin:

After you've posted, open the post again for editing. You'll notice that additional tags were added to your images, I'm not sure by which, Google or this site.

[ img width=352 height=626 ] https://lh3.googleusercontent.com/gBq6HFSFF_ihCKxWMcVCxQI6QP40K-1nLTiG9MYk-IjQ2Uo_DB2dnxD_QETUdkOwZZcPthSXZV31U6vOImuMejmvlK_xtz3lsoa2LoZi53uWto2qhJz6Kt1_Jn4Xs1s6ZNGD7lIHDb9O1hGglnFcDy9g8YVdbW22w45KA8NPoQ5R7d3LDB-baSNX3jlWN9noBEiu6Yyd766HaRbDyzwot_CDzemSu-cG1x6C6L38f19E1WmCIwGAr6jjxUZdVox26jh_JK2C8_C3PPGxpVdgiVZ_Bk1UjyNODO7jG2VBnHGOYlpnmaSNExAMo9h0qTIpKJx7dxBSZYABMrwPbZ4CmxcR_AHpu3MuHcqt66c6PQKqc1xEEB210uvI44RV1Sj7sUOP0HX27T60qZtTzt9SeovHtADnlZv_VQOeqIYrH39eoVIy0IQrAXAU2KXQFGDq08IZ-wYAlMmsNkLeAEIFpeqXwKKLWHfRFmZ3RJNQoMUzTCkVPEDmr-nqAJYOc2F3GRQOsYw45pOfHfl2XjpguLK9oSSIJXXysEifxQ5EmRkXCUhIaG6i-Bv0ETzQDD3nzapw4P8-yallHGdIwsBTrtyG9l8dFQwIxQB1771BnYrmSAjUUsUVJ8kFnaHYJU6rm2Oo1WXgIMc0eXhh1QlIPo6C4M459OyQKcHlpysjIaWVDYjd7D8V5ol1Z7htX6c7r792yCkoGshu1nS4Ow=w353-h626-no

You can change these values to change the image size, for instance "img width=600 height=1200" gives the following result:

(https://lh3.googleusercontent.com/gBq6HFSFF_ihCKxWMcVCxQI6QP40K-1nLTiG9MYk-IjQ2Uo_DB2dnxD_QETUdkOwZZcPthSXZV31U6vOImuMejmvlK_xtz3lsoa2LoZi53uWto2qhJz6Kt1_Jn4Xs1s6ZNGD7lIHDb9O1hGglnFcDy9g8YVdbW22w45KA8NPoQ5R7d3LDB-baSNX3jlWN9noBEiu6Yyd766HaRbDyzwot_CDzemSu-cG1x6C6L38f19E1WmCIwGAr6jjxUZdVox26jh_JK2C8_C3PPGxpVdgiVZ_Bk1UjyNODO7jG2VBnHGOYlpnmaSNExAMo9h0qTIpKJx7dxBSZYABMrwPbZ4CmxcR_AHpu3MuHcqt66c6PQKqc1xEEB210uvI44RV1Sj7sUOP0HX27T60qZtTzt9SeovHtADnlZv_VQOeqIYrH39eoVIy0IQrAXAU2KXQFGDq08IZ-wYAlMmsNkLeAEIFpeqXwKKLWHfRFmZ3RJNQoMUzTCkVPEDmr-nqAJYOc2F3GRQOsYw45pOfHfl2XjpguLK9oSSIJXXysEifxQ5EmRkXCUhIaG6i-Bv0ETzQDD3nzapw4P8-yallHGdIwsBTrtyG9l8dFQwIxQB1771BnYrmSAjUUsUVJ8kFnaHYJU6rm2Oo1WXgIMc0eXhh1QlIPo6C4M459OyQKcHlpysjIaWVDYjd7D8V5ol1Z7htX6c7r792yCkoGshu1nS4Ow=w353-h626-no)

Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 10, 2019, 02:03:41 pm
Thanks Ri!!

I learn more each day!!

 :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Ri on January 10, 2019, 02:06:15 pm
Thanks Ri!!

I learn more each day!!

 :thumleft:

Pleasure! I'm learning a lot from this thread :sip:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: woody1 on January 10, 2019, 02:30:24 pm
On your last post I only see some of the pictures.  Could be our internet at work blocking something.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 10, 2019, 02:44:17 pm
On your last post I only see some of the pictures.  Could be our internet at work blocking something.

Not sure - I can see them all?

Anyone else?

They are hosted by Google Photo - the last posts dated today - all the ones before that were hosted by PhotoBucket?
I will try Flikr as well.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on January 10, 2019, 02:48:53 pm
Where do you find the names for all the bolts and flanges and thingies? It will take me ages to describe! Thanks for the meticulous write-up :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: the_BOBNOB on January 10, 2019, 02:54:04 pm
only seeing some of the photos
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 10, 2019, 02:56:30 pm
Where do you find the names for all the bolts and flanges and thingies? It will take me ages to describe! Thanks for the meticulous write-up :thumleft:

Parts Manual & repair guide as per @noble steed - thanks again for the manual!

Maybe too meticulous - boring....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 10, 2019, 02:57:07 pm
only seeing some of the photos

Shot - I will revert back to PhotoBucket for the moment.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: the_BOBNOB on January 10, 2019, 03:06:36 pm
let me give you a tip on the photos - but dont tell the forum moderators

start a new thread call it "ClimbingTurtle's Photo Thread"

then you post all your photos there no words just a post with photos on it

then you copy the url link from that photo and use it in this thread where you can nicely place it in the correct place

but you did not hear about that from me  :peepwall:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 10, 2019, 03:08:18 pm
And Thanking You will just create an issue - but thanks!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: the_BOBNOB on January 10, 2019, 03:11:08 pm
And Thanking You will just create an issue - but thanks!

nah i'm just joking it should be fine - should not cause any issues

you can attach photos to your posts but if you want to do it nicely with spacing and wording then the current forum software is a little limiting

this way your photos will always be around - not like some ride reports that have no more photos cause the 3rd party hosting is no longer valid
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 11, 2019, 07:27:43 am
only seeing some of the photos

Pls check if some of the pics are still "hidden"
I think they werent "shared" in Google Photos
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 11, 2019, 10:29:15 am
FINALLY – we can see what going on inside the motor

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620980;image)

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620981;image)

And because I failed to read all the words in the manual, I removed the wrong side of the motor, resulting in…

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620982;image)

Surprisingly, there was no rubbish in the bottom of the motor at all, so I checked the bearings and made an assessment of the parts that needed replacement – these include
The Water Pump drive gears (old ones on the right)

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620983;image[url][/url])

The Water pump Bearings

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620984;image)

The water-pump impeller

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620985;image)

The water-pump seals (JOH!!!!)

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620987;image)

And the White Metal Bearings for the Crank – once again, these were sourced from BMW with a 7-day delivery ex-Germany. Damn fine service from Thurston at Auto Alpina in Boksburg I might add.

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620986;image)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 11, 2019, 10:52:46 am
Once I received the White Metal Bearings, I tried to install them, but once I tried it, I realised I would have to make the correct tool for the job – this meant sourcing a piece of 60mm diameter solid nylon rod, sending it out to get a flange turned on it to hold the bearing and a collar to push them into the casing with a hydraulic press. Cost in excess of R1000. Another call to Justin at Motorrad tech to confirm he could press them in for me, but only in January….
So, what to do next…..
I decided to wait for Justin and spend the intervening time cleaning and fixing the rest of the bits that need attention, so lets get washing!!
First was to wash with paraffin and then with degreaser & water – resulting in the area next to the pool becoming a scrap-yard….. 😊

(https://i.postimg.cc/fyQW2Pb2/PIC-5-0.jpg)

Trust me, there are more parts having around being washed – because this is Blitsie just before Christmas….

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620989;image)

And then it was Christmas, so not very much work was done for a few days, except this….

(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=232915.0;attach=620990;image)

Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Edgar on January 14, 2019, 07:46:01 am
It's good to hear that you can get parts so easy and quickly for this project!  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: the_BOBNOB on January 14, 2019, 10:36:43 am
It's good to hear that you can get parts so easy and quickly for this project!  :thumleft:

Yes I'm amazed.

When I had the Dakar it was quicker for me to order parts from MAX BMW in USA than getting stuff from local BMW.

They loved to say "Might take 3 weeks to 3 months" - sorry but how do you run a business like that ???

Well I guess that is why Hammand Motorad closed down  :-\
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: lone riderer on January 14, 2019, 10:43:27 am
Impressive project! Crazy to see the bike torn down like this.

What was the reason for the seizure? I vaguely recall the for sale thread.

What is your general impression of the condition of the mechanics of the bike given the mileage and use?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 14, 2019, 03:51:34 pm
Impressive project! Crazy to see the bike torn down like this.

What was the reason for the seizure? I vaguely recall the for sale thread.

What is your general impression of the condition of the mechanics of the bike given the mileage and use?

I bought the bike with the knowledge that it had heat-seized - apparently due to a water-pump failure.
When i stripped the barrel & piston out, it had not seized, in fact it was in very reasonable condition - so much so that after a bath in parrafin, i sent it off to be hermatically measured  :biggrin: :biggrin: - in a temperature & humidity controlled measuring room, the barrel & piston both came back well within original spec. I did not replace either, but I have put new rings in, purely as a precaution and as the motor was open. I was extremely happy with the mechanical component condition and I am happy with the bits I have done.

The rest of the motor, gearbox etc., is in pretty fine condition. I measured runout and thrust washer thickness tolerance - all within spec, same with the selector fingers and all the gears. I replaced the waterpump, complete with the seals and drive gears (you have to split the motor for this)
 The output shaft splines are worn, but thats not in the budget (sadly) at the moment. I have however replaced the white metal bearing on the crank (R2500 per set of 4 halves) and all the roller bearings in the motor (R500 from BMG) as well as the wheel bearings, chain rollers, and steering head bearings.
Also replaced all the bushes in the suspension, along with the seals.

There is a fair amount of general wear on the bike (plastics have had a hard time) and the chain has eaten a small section of the underside of the swingarm where it wore through the slider strip - and into the bearing cage..... This will be dressed, but thats all.

These are apparently pretty strong bikes - although I have not got to a point anywhere near starting it - I did manage to start motor assembly this weekend, but I forgot to do valve stem seals (I have them already, just forgot to do the job), so that will wait till Saturday morning when I can get to Halfdaft.

In the emantime I also have a XT500 that is nearing completion.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on January 15, 2019, 01:21:11 pm
Impressive project! Crazy to see the bike torn down like this.

What was the reason for the seizure? I vaguely recall the for sale thread.

What is your general impression of the condition of the mechanics of the bike given the mileage and use?

I bought the bike with the knowledge that it had heat-seized - apparently due to a water-pump failure.

There is a fair amount of general wear on the bike (plastics have had a hard time) and the chain has eaten a small section of the underside of the swingarm where it wore through the slider strip - and into the bearing cage..... This will be dressed, but thats all.
/quote]

Interesting that the damage on the bike was everywhere else but the piston and sleeve - where you expected it most.
I sell lots of BoosterPlugs to keep especially air cooled R1200's cool (a small bit of petrol to cool down the pistons and valves) to prevent piston seizure and wear (pistons expand due to heat and start wearing away against the sleeves, also causes temporary seizures). Apart from this, I have had rave reviews from 650 single owners saying that their bikes go much better.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Sandvreter on January 21, 2019, 02:59:48 pm
If you dont mind , please do tell us at aome point where you actually managed to source most of the parts please?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 21, 2019, 03:34:00 pm
If you dont mind , please do tell us at aome point where you actually managed to source most of the parts please?

All the bearings and seals are available from BMG (Bearing Man)
All the other bits came from BMW - Auto Alpina in Boksburg - BMW SA carries a lot of the items off-the shelf in Midrand, so i get them the next day.
Startline has a pretty good range on "consumables" - so bulbs, brake pads, indicators, brake levers, cables, chains - even clutch plates!
And a few items from this forum.....

I will continue with the report tomorrow - work is very interfering.....
 :P
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on January 31, 2019, 01:19:59 pm
Here is what we have currently – lets just assume that “Some Assembly required” will cover it….

(https://i.postimg.cc/4d9N1GXH/PIC-5-3.jpg)

Another part that received attention was the front engine mount – the twin spars that hold the front of the engine and the bash-plate and rad – circled in red…..

(https://i.postimg.cc/QCg8Rq9X/PIC-5-4.jpg)

The one mount was broken – the cap-screw snapped off in the alu upright – I tried heat, force with vice-grips – nothing doing…

(https://i.postimg.cc/L895FG3G/PIC-5-5.jpg)

So onto plan “B” – made up a small bracket out of a double-layer of flat bar, welded together, with another piece welded on at 90-deg. This will keep the drill at 90deg in 2-axis.

(https://i.postimg.cc/rpbwWs2L/PIC-5-6.jpg)

I then drilled a small 1.5mm hole in the end of it and on the reverse side, drilled a shallow 6mm hole – this will use the damaged M6 capscrew to “locate” the centre of the damaged capscrew. Ground the capscrew flat and used the 1.5mm pilot hole to drill the centre of the capscrew.

(https://i.postimg.cc/vHLTjGfW/PIC-5-7.jpg)

Drilled it all out to 3mm and tried a Eez-out – nada……
Then drilled it to 5mm and used a M6 tap and re-cut the thread. Job Done…..

(https://i.postimg.cc/J7jzDRT9/PIC-5-8.jpg)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: lone riderer on February 02, 2019, 07:45:22 pm
love that first photo, the XC as sculpture!

You will literally know this bike inside out in the end  O0
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on February 04, 2019, 08:39:30 am
Yup = thank you!
I can completely strip the X without a manual now - but its been a steep learning curve!
I got a complete new rear mudguard from @alwyn_gs on Saturday - thanks Alwyn, much appreciated - this will go a long way to sorting everything out.
As the new rear mudguard id blue, I am thinking about getting the whole bike wrapped in BMW blue, with white accents,  instead of the other way around - I will see when we get to that point!

more to follow.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: GRUNT on February 18, 2019, 04:11:31 pm
14 days later, after checking everyday, still nothing?...... Blitsie deserves better than this!!! :'(
come now young man, pull finger!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on February 19, 2019, 07:26:42 am
14 days later, after checking everyday, still nothing?...... Blitsie deserves better than this!!! :'(
come now young man, pull finger!

 :imaposer:
Some progress was made - but I took 10 days off and went to North Natal to chill with the family a bit
Will see what I can do about posting later....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on February 19, 2019, 01:56:05 pm
So – onto the bearings – firstly was the front & rear wheel bearings – used a brass rod to hammer them out, and installed with a long M10 threaded rod – also heated all the hubs with a heat gun, and left the bearings in the freezer for an hour, add a little Q20 to the mix – pretty much went as per the plan!!

(https://i.postimg.cc/SNhLSHr6/PIC-5-9.jpg)

(https://i.postimg.cc/6p6dRRFT/PIC-6-0.jpg)

Also did the steering head bearings – pretty knackered as you can see!!

(https://i.postimg.cc/9XTtjcGX/PIC-6-1.jpg)

(https://i.postimg.cc/2SHnxyfG/PIC-6-1A.jpg)

(https://i.postimg.cc/wTQX7FfS/PIC-6-2.jpg)

And assembled the steering – ready to go back onto the frame!

(https://i.postimg.cc/6QgRDPqG/PIC-6-3.jpg)

And then the 2 casings arrived back from Justin at MottorradTech – he pushed the half-shells into the casings for me – and didn’t charge….. Brilliant service once again!!

But then I decided that while the motor was split, I may as well replace all the roller bearings as well – back to BMG – another R497, so not bad at all – I am pleased!

(https://i.postimg.cc/HLVXvmYg/PIC-6-4.jpg)

All nice & Shiny!

And then add this...

(https://i.postimg.cc/j5fNKhn3/PIC-6-5.jpg)

And this

(https://i.postimg.cc/3NHGwDg8/PIC-6-6.jpg)

Please note the 2 necessary pieces of equipment, one only at the end of the day tho… The laptop with the instruction manual and a beer to try and calm down…..

(https://i.postimg.cc/x8yzNTRK/PIC-6-7.jpg)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on February 19, 2019, 04:20:45 pm
Mmm - an empty beer bottle☺
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Ri on February 19, 2019, 04:24:26 pm

Please note the 2 necessary pieces of equipment, one only at the end of the day tho… The laptop with the instruction manual and a beer to try and calm down…..

(https://i.postimg.cc/x8yzNTRK/PIC-6-7.jpg)

Oooooooooh SHINY :drif:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: GRUNT on February 19, 2019, 09:50:57 pm
Good going and welcome back! :biggrin:
I really enjoy this thread, following the progress keenly, can't wait till Blitsie's dignity has been restored :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on February 20, 2019, 11:56:21 am
Right – added a new gasket to the to halves and joined them up – bolted them together and torqued down as per the manual – things are looking good!!

Next job was to replace the valve stem seals – which involved a trip out at @Halfdaft to use his valve compressor tools – and then a few hours of valve-seat grinding – may as well get this done properly hey?

(https://i.postimg.cc/FKZ0xynp/PIC-6-8.jpg)

Once back home, I battled with the valve spring compressor tools until I decided just to go and buy a proper set – and then it was job over in 10 minutes – money well spent!!

(https://i.postimg.cc/zf173qVg/PIC-6-8B.jpg)

So, the order of events dictates that the next step is to install the barrel on the piston – now, I have a very fine piston ring compressor, however its not a split type, so is rendered useless by the fact that the head slides onto the barrel that’s already attached to the con-rod, instead of installing the piston in the barrel and then attaching the con-rod to the crank. So we need to make a plan – which is done with a piece of plastic from a margarine tub, and a 104mm diameter heavy-duty hose-clamp from Steelmate – oh, and a whole load of patience….

(https://i.postimg.cc/g23VxFVf/PIC-6-9.jpg)

Next – torque the head down and install the cam chain – making sure the timing marks are correct. I have to say at this point that BMW makes all of this very easy making idiot-proof marks and an ingenious groove ground onto the bottom/side of the crank (Pic Below in yellow), that locks and locates TDC with a tapered allan bolt – locks everything up so that you can torque bits – ingenious!

(https://i.postimg.cc/653mN6v6/PIC-6-7B.jpg)
(https://i.postimg.cc/wTycds7x/PIC-7-0.jpg)

Next was to install the motor in the frame – this posed its own problems as I don’t have an overhead crane to lower the frame onto the motor.
Some 3 hours later, a little loss of skin, a reprimand from the neighbour regarding my language within hearing distance of his 5-year old daughter, and the inventive use of 3 jacks – one to hold the bottom of the motor, one to lower/raise the front of the motor (so it swivels on an axis) and one to lower the frame – I managed to get it all in by myself…..

(https://i.postimg.cc/7YF1PY23/PIC-7-1.jpg)

The filter box ontop is to make me feel good….
The eagle-eyed will also notice that the side-covers on the motor are not on – on either side – this is because they clutch basket on one side and the magneto on the other need to be torqued to stupid values and I decided that woud be easier to accomplish with the motor in the frame – its was…..

(https://i.postimg.cc/25m4vcT3/PIC-7-2.jpg)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on February 20, 2019, 11:58:36 am
Oh - forgot - I was doing the piston/head installation on a Saturday - and then I tore the base gasket....

 >:(  >:(  >:(  >:(  >:(  >:(  >:(  >:(  >:(

Needless to say, BMW was already closed - so I had to wait for Monday to order a new one - patience is apparently the name of the game here.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Piet on February 20, 2019, 12:24:43 pm
 :happy1: I love this thread! Thanks for the update CT!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: billy-joe on February 20, 2019, 05:46:49 pm
sub'd!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: alwyn_gs on February 26, 2019, 08:01:17 am
 :o naaaaice progress



Patience is a virtue....  :pot:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on February 26, 2019, 12:18:27 pm
Patience young Padawan - all will be revealed....

OK - so progress was a little slow - but I have been battling with nothing of pictorial consequence - ie: wrapping and sorting the wiring harness...

Post to follow.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on February 26, 2019, 03:02:25 pm
So next was to install all the missing motor bits – clutch basket, magneto, starter motor, oil tank, and then start on the radiator and at some point get my head around the wiring – that’s making me nervous….

(https://i.postimg.cc/wvRtyhJF/PIC-7-3.jpg)

Around about this point, I got my hands on a coating kit for Zinc Coating parts – a deposit on a XT500 I sold – so I started with some nuts & bolts and the left footpeg….
WINNER!!

(https://i.postimg.cc/25KbSHqV/PIC-7-4.jpg)

So that obviously went on…

(https://i.postimg.cc/5t0Q1c2h/PIC-7-5.jpg)

Last major job was the rear swingarm bearings – these are caged roller bearings and I was a little apprehensive bout pushing them in without a press and with my other favourite too – the hammer…..
Anyway, I cleaned up the damage caused by a rampant chain and no chain rails

(https://i.postimg.cc/sgKGtfsP/PIC-7-6.jpg)

Then in with the bearings – after heating the swingarm to Too-hot-to-handle temp and freezing the bearings and the gentle taps of the persuader using a socket as a guide and they were in!

(https://i.postimg.cc/6pBGj4J5/PIC-7-7.jpg)

(https://i.postimg.cc/ryW0qNqw/PIC-7-8.jpg)

(https://i.postimg.cc/YC2hfcYv/PIC-7-9.jpg)

Assembly went as planned, added the chain guard & rollers and then….
YUP – big moment for me - installed the rear shock…
And please note the shiny coated cap-bolts to hold the footpegs on…..

(https://i.postimg.cc/htCh2C1p/PIC-8-0.jpg)

Whilst I was there, I added this…

(https://i.postimg.cc/4NgKyH3b/PIC-8-1.jpg)

And this…!

(https://i.postimg.cc/Hs9ryWcG/PIC-8-2.jpg)

And then it was on to the wiring harness.

(https://i.postimg.cc/V6t6LzQV/PIC-8-3.jpg)

I decided to remove much of the old wrapping – old non-sticky insulation tape, and check and repair the wiring as needed – as it happened, not much was required – just a couple of wires worn through, repaired and then the whole harness was re-wrapped.

(https://i.postimg.cc/Lsw5pn7P/PIC-8-4.jpg)

Please not the computer box indicated by the red arrow – this haunted me for a few hours on Sunday afternoon, the whole night of dreams and most of Monday at work – I could not for the life of me remember where I had removed it from, and by default, where to put it back….!

(https://i.postimg.cc/FK7z8jPm/PIC-8-5.jpg)

By using the Spark plug leads as reference points I worked out where it needed to be, and Google and looking at photos from where I stripped the bike, I worked out where to fasten it in – took more than one try….


People - I am getting excited......!!   :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Piet on February 26, 2019, 03:16:20 pm

People - I am getting excited......!!   :biggrin:
So are we!  :biggrin: Good progress - almost done!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Supervan on February 27, 2019, 05:11:55 pm
What a flippen nice thread.  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Kaboef on February 27, 2019, 05:45:02 pm
Great stuff!!

Very impressive.


Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ChrisL - DUSTRIDERS on February 27, 2019, 06:05:06 pm
Very very nice, you should do this more often!! :deal: :thumleft: :drif:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on February 28, 2019, 01:16:48 pm
I don't even want to think how many hours have gone into this!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on February 28, 2019, 01:44:26 pm
I don't even want to think how many hours have gone into this!

I dont count them - its not worth it.....  :biggrin:

I mainly do this for amusement, I either sell the bike at the end, or keep it - depending on what I want out.
I sold a XT500 last week that I did a load of work on - the new owner got a damn fine, registered, on the road XT that starts first kick for R20k - with a load of new parts in it.....

Then I look for another one - the wife doesnt mind too much, I set a budget and stick to it as much as possible - although the XC budget is pretty much at is max already, and I still need brake discs, pads & tyres - but if i sell my GSA, i will keep this and add some extra stuff to it, upgrade the suspension, add fuel, swap out the rims etc....
It also keeps me out of the pub, relatively sober (mostly, anyway) and I get to listen to some tunes while i work - and I have amassed a huge number of tools needed to do funny jobs, along with the knowledge that comes with a complete strip-n-build - its fun!!

We shall see!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Edgar on February 28, 2019, 04:34:00 pm
Looking very good man.  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 04, 2019, 03:04:50 pm
Not so much of pictures today - basically the before and after pics are the same - the difference is 5 days spent tracing wiring - and the discovery that the correct wires that plug together change colours at the plug connector blocks......  :eek7:

So @superfoxi sent me a wiring routing diagram - many thanks Mike - basically shows me where the sections sit in relation to the frame 7 panels, might sound minor, but if its out you cant get things to reach....

Next step was to plug the individual sections in - herein lies the rub - there are a whole load of different connector blocks that are the same - the FI management and the Oil pressure gauge for example, and the water temp and the rear wheel speed sensor - mix these up and the main issue will be that it wont start.....

After 5 days search in the Interwebs, I finally found Mattsnook.com - he has a X-Country that has more mods than most of Brakpan combined with Springs - and hidden way down in there, there was a file with the coloured wiring diagram - all 5 pages for a non-ABS model - and some more searching to work out the wiring colour codes (WSGE is White with Yellow stripes.....) and then we were away - It took the balance of Sunday to check the wires were plugged in and correct.....

Next was fluids - can you believe we are ta that point? And a new battery......
Then it wa bridge the wires from the ignition (key is broken) and then the motor turned over and completely failed to start.......  :imaposer:

In all fairness, I would have been stunned if i got 2 bikes in a row to start first try (My last XT Project started first Kick - i kid you not!!) - there seems to be quite a drag on the system - so either the battery is not that well charged, the starter is labouring - and the whole system seems "slow" - so I will re-oil the piston tonight, I have charged the battery, and we will see - it NEARLY fired last night - gave a quick Stutter and then went back to cranking.....

Failing that, back to trouble-shooting!

Nearly there people!!

 :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: GRUNT on March 04, 2019, 06:30:33 pm
Fantastic! well done, I cant wait for the pics of this bike when up and running :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 08, 2019, 08:38:28 am
Blitsie is Running!!  :ricky:

After trouble-shooting the wiring, I discovered that the Spark Plug Leads were the wrong way around - in my defense, this was stripped when I picked the bike up, and I did not know the correct order - so after a bit of research, sorted.
Added battery, started in 4 seconds, straight to a decent idle....
Today we see if we can button up all the loose ends - sprocket, chain, one non-working indicator, re-check oil, check the fan, adjust the brakes & clutch, add the body panels - hopefully we do a short test ride later this afternoon...

Pics to follow!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Black_Hawk on March 08, 2019, 09:21:59 am
Well done CT  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: noble steed on March 08, 2019, 06:13:26 pm
Blitsie is Running!!  :ricky:

After trouble-shooting the wiring, I discovered that the Spark Plug Leads were the wrong way around - in my defense, this was stripped when I picked the bike up, and I did not know the correct order - so after a bit of research, sorted.
Added battery, started in 4 seconds, straight to a decent idle....
Today we see if we can button up all the loose ends - sprocket, chain, one non-working indicator, re-check oil, check the fan, adjust the brakes & clutch, add the body panels - hopefully we do a short test ride later this afternoon...

Pics to follow!

Glad you have the motor running!

I found indicators to be a pain to troubleshoot, as they're all wired through the instrument cluster, no discreet flasher relay. After a couple weeks trying to get it sorted including trying to treat the cluster PCB for any corrosion etc, I eventually got wiring diagram for cluster, cut the indicator wires going into it and ran a separate circuit via an indicator flasher relay. Indicators have worked well since!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Oubones on March 08, 2019, 06:52:46 pm
Well done! :thumleft:
If I ever need to buy a bike again, I think I must come and get one of your rebuilds! :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 09, 2019, 09:57:37 am
Blitsie is Running!!  :ricky:

After trouble-shooting the wiring, I discovered that the Spark Plug Leads were the wrong way around - in my defense, this was stripped when I picked the bike up, and I did not know the correct order - so after a bit of research, sorted.
Added battery, started in 4 seconds, straight to a decent idle....
Today we see if we can button up all the loose ends - sprocket, chain, one non-working indicator, re-check oil, check the fan, adjust the brakes & clutch, add the body panels - hopefully we do a short test ride later this afternoon...

Pics to follow!

Glad you have the motor running!

I found indicators to be a pain to troubleshoot, as they're all wired through the instrument cluster, no discreet flasher relay. After a couple weeks trying to get it sorted including trying to treat the cluster PCB for any corrosion etc, I eventually got wiring diagram for cluster, cut the indicator wires going into it and ran a separate circuit via an indicator flasher relay. Indicators have worked well since!

Cheers - turned out there was no bulb,,,,,  :o
Works fine now!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 09, 2019, 10:04:07 am
OK - couple of pics you reckon?

Herewith the Resurrected Blitsie!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 09, 2019, 10:05:58 am
Then I realized  that I left the bash-plate off - so with that fixed, and a new set of UBag6's on him - here we go - ready to ride!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 09, 2019, 10:19:25 am
So the next bit was a blast around the suburb - with the new luggage, may as well test that too hey?

Result?

Blitsie handles well, didnt open up too much with the new engine bits, but on returnafter 10km, discovered a couple of issues - small, I hope....

A couple of drops of oil at teh bottom of the clutch cover - re-tightened the caps and also tightened the drain plug a little as well - it wasnt massive, but it must be gone.

Second issue was a little more serious - overheating and pissing coolant out of the radiator cap, all over everywhere - best we attend to this!!

So, things to check - the fan (I Know it works with power) doesnt appear to come on, so best we check the thermostat, and do a little research....

Bearing in mind, the initial problems with Blitsie started with heat-seizing, so I reckon we need to do some stuff...!!

All good tho, at least we know what we need to do!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Kamanya on March 09, 2019, 10:57:09 am
I love threads like this.

Moaaarr!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 10, 2019, 11:48:14 am
@ClimbingTurtle Check that you don't have an air bubble in your cooling system. Since a bubble can cause the coolant to overheat and spill over before the fan turns on. Thermostat is easy to check with a cup of hot water and dipping the thermostat into it.If you pouring the coolant back in just squeeze the coolant hoses while you pouring it back in then just close the cap run the bike to operating temperature then just shut it off and cool down then reopen the radiator cap and squeeze the lines again and fill the rad to the top. That should get all the air out. .
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 11, 2019, 07:29:37 am
Cheers Superkrazy - i did most of this, still no fan and boiling coolant....
But seeing as this is a resto-project, we must expect the odd hiccup and stumble on the way, so with that in mind I started trouble-shooting.

Obvious place to start is the fan - add a power cord an that runs furiously - so thats fine.
Next place to look is the heat-switch on the head that runs the fan - as soon as I un-clipped it with the ignition on, the fan comes on - so potentially the heat-switch is faulty, but I can only confirm that when the rest of the system is confirmed as being 100%
Drain the coolant - and seeing as the drain plug is part of the coolant pump, whip the cover off and confirm the gears are engaged - they are, so thats all good.
Next - whip the coolant hose off of the bottom of the rad and check the thermostat, and this is the result.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 11, 2019, 07:37:58 am
Now, this is probably the start of the original problem re the heat-seizing.....

So, back to BMW and order a new thermostat, and the rubber seal while we are at it - pointless not to do that when its apart....!
Also, on inspecting the radiator cap, the "ears" were bent a little unevenly, so it was never going to seal properly - bent them a little and thats now sealing

Then I reassembled, filled with coolant, bled the system and started him up again, ran up to temp - but even before that, coolant started pushing out of the bottom of the section where thermostat sits - so the seal is probably not seated properly, or there is shrapnel in there, or something..... I switched it off to think......

BUUUUT....... The concerning bit, is where are the rest of the damaged parts - there is a black cap missing from the top of the thermostat, along with some other plastic shards - there should be more pieces!!

The good news is that when I stripped the motor, i checked all the water channels, so no debris in there - and the damage occurred before the rad, so I suspect the pieces are stuck in the top of the rad somewhere - not ideal, admittedly......

I the applied some sustained thought and went and had a beer and a swim.......

Tonight i will take the rad out completely and inspect properly!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 11, 2019, 02:05:59 pm
@ClimbingTurtle Just for good measure do a cooling system flush. Since you get some knobs using normal tap water and coolant and mix in the system, this can cause calcification buildup in the engine cooling channels and the radiator. Also check that your cooling system pressurizes at least as you are saying there are pieces missing and the radiator cap was bent. If you don't want to bother with a fan switch just wire it manually so that you can leave the fan on when hitting the trails.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 11, 2019, 02:10:30 pm
@ClimbingTurtle Just for good measure do a cooling system flush. Since you get some knobs using normal tap water and coolant and mix in the system, this can cause calcification buildup in the engine cooling channels and the radiator. Also check that your cooling system pressurizes at least as you are saying there are pieces missing and the radiator cap was bent. If you don't want to bother with a fan switch just wire it manually so that you can leave the fan on when hitting the trails.

Thanks - yup, will probably do that all tomorrow - ordered a new cap, O-ring & Thermostat from BMW this morning - it will be here tomorrow - so tonight I will strip the rad off and check it out properly - may as well remove it and do it properly, its only a couple of bolts! The temp sensor switch is also under R400 - but I will only do that if it still doesn't start the fan - I discovered the fan comes on when you disconnect the plug on the switch (I thought I was going to have to bridge it)
We will know later today!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 11, 2019, 07:23:24 pm
Just fyi for the future. You don't have to get only bmw parts you can also use aftermarket parts which are just as good and 1/3 the price.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 12, 2019, 07:22:52 am
Just fyi for the future. You don't have to get only bmw parts you can also use aftermarket parts which are just as good and 1/3 the price.

Thanks - I probably could have, but I am in a rush, and I dont have time to wander around looking for stuff - the O-ring would have been easy to get, and the cap wuld have been OK to, not sure abou the thermostat, but then I havnt looked!!

Coolant volume - total is 1.1 litres - that very little - and thats why I thought there might be blockages, still going to blow all the galleries out tonight & install the parts and see.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 13, 2019, 07:52:13 am
OK - Seems that we have solved that little problem... Well, 3 problems actually...

 - Thermostat disintegrated - pic of the old bits and a new unit (I forgot to take a pic!)
 - O-ring - the old one was worn and had some calcification on it - stupid not to replace it
 - Radiator Cap - looks like the wrong one was installed - the old one is on the left - although they were the same pressure rating (1.5Bar) the old one would not have had the space to move, as far as I can tell....

(https://i.postimg.cc/WbdpVxjd/PIC-8-6.jpg)

(https://i.postimg.cc/D0M2sPQf/Thermostat.jpg)

(https://i.postimg.cc/ZY7Y1Jkk/PIC-8-7.jpg)

Then I filled up the coolant, started Blitsie and ran him until the fan came on - which it does, so theheat switch is actually working!!
Then I ran out of time to re-assemble the panels etc., so the test ride will wait until tonight!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Piet on March 13, 2019, 08:05:25 am
Great news! Well done, CT!  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on March 13, 2019, 08:44:26 am

@ClimbingTurtle, that original pressure cap is incorrect.  That comes from the old F650 Funduro and a completely different cap,  The new one is the correct one.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 13, 2019, 08:49:24 am

@ClimbingTurtle, that original pressure cap is incorrect.  That comes from the old F650 Funduro and a completely different cap,  The new one is the correct one.

Cheers - that arrived with Blitsie - albeit in a box, so I assumed it was the correct one - but clearly not - thanks for the confirmation!!

 :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on March 13, 2019, 09:32:53 am

@ClimbingTurtle, that original pressure cap is incorrect.  That comes from the old F650 Funduro and a completely different cap,  The new one is the correct one.

Cheers - that arrived with Blitsie - albeit in a box, so I assumed it was the correct one - but clearly not - thanks for the confirmation!!

 :thumleft:
This is the problem when taking care of someone else's problems, and the beauty of taking personal ownership. Clearly this jockey is on the right track! Wll done Turtle☺
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 18, 2019, 08:11:39 am
Right - a weekend of problems, solved & unsolved was had....

Firstly, the coolant issues - after a morning of trouble-shooting at @Halfdaft - including pressure-testing the rad.
the problem is the boiling coolant and then it overflows before the fan comes on.....
The decision was that I had buggered up the coolant ratio, so off to the Engen to aquire some new BMW-blue coolant, drained, measured accurately to 1100ml and filled - tested and voila! No boiling, no overflow, no issues.....

So, off to test it Sunday morning, packed some spare coolant and a few spanners, a tube & a pump and met Richard at 7am at the R59 Blockhouse North, for some technical track riding - oh man, what a blast, 2 hours of riding and I was properly tired, seriously unfit for the tight & twisty riding, but what a blast, had some of the best riding done in ages, I would not have liked to do this on my 1200 though..... The fan came on a couple of times, but no warning lights, and given the slow rate of progress, and the thick, high grass at some sections, I was extremely pleased with this!

After a couple of hours, and with some other plans for the rest of the day, I trailered up and headed home and washed Blisie of the mud & dust, and to check fluids.....

Oil - clear, full, no issues.
Overflow bottle - hasnt moved off of the mark.
Rad - just about DRY!

WTF!!??!!?? - the coolant in the rad has disappeared! Load up the 60ml syringe and start adding premixed coolant - added 190ml, including some burping....!!

So clearly the problem is not solved.......

Blitsie is running perfectly, no water in the oil, yet has vanishing coolant.....

Who has ideas.......  :-[
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ktmmer on March 18, 2019, 08:23:21 am
It had an air lock (bubble) which bled out. 

Fill it and give it a good ride and check again.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 18, 2019, 08:39:05 am
There can only be  a few problems that causes coolant issue:
1. air bubble
2.Broken water pump(did you test the new one you put in?)
3.hole in rad or hoses
4.calcification.
5.blockage in rad
6.broken thermostat (did you test the new one before putting it in?)
7.incorrect coolant fill level
8.Incorrect air/fuel mix so bike is running lean boiling coolant(happened to my dakar when I added mods so just made it more rich fixed the issue)

Check this list and tick them off, if anyone wants to add to list go for it so we can help a fellow dog out to enjoy his new beasty.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 18, 2019, 09:17:47 am
There can only be  a few problems that causes coolant issue:
1. air bubble - I pumped the hoses and leaned the bike over - coolant was 1100ml
2.Broken water pump(did you test the new one you put in?) tested - removed the impeller cover, bumped the motor, it spins
3.hole in rad or hoses pressure tested rad, all good, visually checked for leaks - nothing found!
4.calcification. possible.... I could add a weak vinegar solution?
5.blockage in rad Rad appears to flow - we temperature tested the inflow & outflow coolant temperature, it flows out a good 10 deg cooler than the in-flow.
6.broken thermostat (did you test the new one before putting it in?)  Thermostat is new - i did not test it prior to installation, howver we believe it works as the rad stays cool until a point, then the hot water starts flowing through when the thermostat opens
7.incorrect coolant fill level Filled to the bulge on the neck of the rad where the cap fits in, after burping - a measured 1150ml was added, and i spilled a little from the drain plug on the right
8.Incorrect air/fuel mix so bike is running lean boiling coolant(happened to my dakar when I added mods so just made it more rich fixed the issue) No idea how to change this, its all run by the ECU, or can you adjust it?

Check this list and tick them off, if anyone wants to add to list go for it so we can help a fellow dog out to enjoy his new beasty. this bike is a revalation - I rode @Halfdaft 's XR650L a while back when we did Lekgalameetse, it was brilliant, but this handles completely differently! I am digging the fast steering, makes ruts & single-track a real pleasure!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 18, 2019, 09:36:43 am
Fill it then ride it and then fill again. Maybe this will solve a stubborn air pocket.Test a 3rd time and check if it helped.
Did you do any mods to the motorcycle like aftermarket exhaust/air fitler etc?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 18, 2019, 09:44:09 am
Fill it then ride it and then fill again. Maybe this will solve a stubborn air pocket.Test a 3rd time and check if it helped.
Did you do any mods to the motorcycle like aftermarket exhaust/air fitler etc?

Thanks - I will try this - the fact that I added the correct amount of coolant made me think it was OK - but I will try again, and a third time if necessary!

Aftermarket - it has a Leo Vince on it, but not new, ie: it was on the bike for a while before I took the bike over - no other mods.

The bike just goes so well - starts first bump, idles immediately, its such a pleasure to ride! I really need to get to the bottom of this.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 18, 2019, 09:59:29 am
Have you checked maybe for a leaky radiator or hose? It might have a hole in it and under load it starts leaking slowly and this might cause coolant loss and overheating issue.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 18, 2019, 10:05:49 am
Have you checked maybe for a leaky radiator or hose? It might have a hole in it and under load it starts leaking slowly and this might cause coolant loss and overheating issue.

Exactly what HalfDaft just suggested - that the Rad is OK up to 1.1Bar, but leaks at 1.2-1.5Bar (or the pipes), so I am going to clean the motor nicely later today, then ride around the neihbourhood for 40-50km and see whats what then.

I would hate to have to replace the rad.... $$$$$$
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 18, 2019, 02:40:17 pm
You can braze a radiator for very cheap no need to replace the radiator if there is a hole. Put the bike on a stand and kick the revs up for a while then look around for leakage around the hoses and the radiator front and back side. Do this with the fairings off to have a better view of of everything. Also wipe with a paper towel and see if you get any dampness when wiping.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 18, 2019, 02:57:43 pm
You can braze a radiator for very cheap no need to replace the radiator if there is a hole. Put the bike on a stand and kick the revs up for a while then look around for leakage around the hoses and the radiator front and back side. Do this with the fairings off to have a better view of of everything. Also wipe with a paper towel and see if you get any dampness when wiping.

More or less what we did on Saturday - even dried the rad out with a compressor (softly) - didnt actually see any seeping...

The sides of the Rad are plastic (the end-caps) where the thermostat fits in, so I dont think the can be brazed..... But, I am certainly prepared to send it out for a look - Silverton radiators I suppose?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 18, 2019, 03:02:36 pm
Plastic weld type of products works great on plastics same with some epoxies and jb-weld also. There are a wide range of diy products to fix a leak. Have you checked the fin pipes front and rear of the radiator for any dings?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 18, 2019, 03:06:42 pm
Just fyi bend some of the hoses under pressure as holes can open under movement and standing still can seal them back up. This happened to my front rad hose that had a stress fracture and only leaked when going over bumps so took me a while to find out it was a hose that's leaking.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 18, 2019, 03:09:00 pm
Just fyi bend some of the hoses under pressure as holes can open under movement and standing still can seal them back up. This happened to my front rad hose that had a stress fracture and only leaked when going over bumps so took me a while to find out it was a hose that's leaking.

Thats worth a shot!!  :thumleft: Give that a try this evening.

Also going to mix up some epoxy and layer it around the rad cap area - saw a thread about pin-holes on AdvRider.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 18, 2019, 04:16:29 pm
Just make sure you sand and clean the area if you going to epoxy onto smooth areas. This will promote adhesion.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ktmmer on March 18, 2019, 05:51:58 pm
Just fyi bend some of the hoses under pressure as holes can open under movement and standing still can seal them back up. This happened to my front rad hose that had a stress fracture and only leaked when going over bumps so took me a while to find out it was a hose that's leaking.

Thats worth a shot!!  :thumleft: Give that a try this evening.

Also going to mix up some epoxy and layer it around the rad cap area - saw a thread about pin-holes on AdvRider.....

Maybe rather find the leaks and have it tig welded. Epoxy will contaminate the material if you decide to weld later.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 19, 2019, 07:55:05 am
Just fyi bend some of the hoses under pressure as holes can open under movement and standing still can seal them back up. This happened to my front rad hose that had a stress fracture and only leaked when going over bumps so took me a while to find out it was a hose that's leaking.

Thats worth a shot!!  :thumleft: Give that a try this evening.

Also going to mix up some epoxy and layer it around the rad cap area - saw a thread about pin-holes on AdvRider.....

Maybe rather find the leaks and have it tig welded. Epoxy will contaminate the material if you decide to weld later.

Its plastic, unfortunately - this is the issue actually - the sides, where the thermostat sits and the in-flow & out-flow and over-flow pipes connect, are all plastic..... The core is alu I assume?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: BullFrog on March 19, 2019, 09:05:23 am
Just put an egg in there!!!!  ::) ::)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 19, 2019, 02:23:04 pm
Just put an egg in there!!!!  ::) ::)

And then we have cooked egg in the radiator.....  :eek7:

Because there is no leak......

 :patch:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 19, 2019, 02:38:01 pm
OK - so this morning I loaded Blitsie onto the trailer and off to Silverton Radiators in Benoni.....

First - pressure test - 1.5Bar - no drop in pressure.
Was then advised to strip the rad out, and bring it in for more testing, so off home, drain coolant, strip out the rad, back to Silverton Radiators, luckily not too far....
Secondly was a air-pressure test - plugged all the pipes (overflow bottle still attached), add some air pressure, immerse in the water-tank - no bubbles at all.....
Bear in mind the overflow is also in the system at this point, as they use a cap without a spring pressure in it.
Thirdly, they then caustic cleaned it - to get out any calcification in the core - and water-pressure tested it again - no air-bubbles in sight.

They declared the radiator to be completely leak-free - I have to agree with them...

Also, they didn't charge me for the testing...... What a nice place - I will go back there!!

So, we know all the areas it isn't, but not the areas it is causing a problem.....

So Thursday, we ride again.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: BullFrog on March 19, 2019, 02:43:38 pm
Just put an egg in there!!!!  ::) ::)

And then we have cooked egg in the radiator.....  :eek7:

Because there is no leak......

 :patch:

In jest.....

Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 19, 2019, 02:49:56 pm
Just put an egg in there!!!!  ::) ::)

And then we have cooked egg in the radiator.....  :eek7:

Because there is no leak......

 :patch:

In jest.....

I know.....  :laughing4:  :imaposer:

I was looking at more modern versions of the egg as well - but the result is still..... No Leak.....   :pot:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on March 19, 2019, 03:19:30 pm
Make sure the engine is cold.  Pull the sump plug but only allow the oil to seep out slowly.  Collect this oil in preferably a clear glass jar.  You only need to drain about 100ml.  Once it has settled, check if you have any coolant on the bottom of the jar.

I am assuming you fitted new waterpump seals.  Are you sure you put them in back to back, and not facing the same direction?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 19, 2019, 03:26:56 pm
Make sure the engine is cold.  Pull the sump plug but only allow the oil to seep out slowly.  Collect this oil in preferably a clear glass jar.  You only need to drain about 100ml.  Once it has settled, check if you have any coolant on the bottom of the jar.

I am assuming you fitted new waterpump seals.  Are you sure you put them in back to back, and not facing the same direction?

Thanks - will do this tonight as well..... The oil is all nice and new as well.....

New water-pump, with seals - correct facing direction as well - new drive gears too - pump works correctly, i stripped the cover off and bumped the motor to confirm they are turning.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on March 19, 2019, 04:09:33 pm
Make sure the engine is cold.  Pull the sump plug but only allow the oil to seep out slowly.  Collect this oil in preferably a clear glass jar.  You only need to drain about 100ml.  Once it has settled, check if you have any coolant on the bottom of the jar.

I am assuming you fitted new waterpump seals.  Are you sure you put them in back to back, and not facing the same direction?

Thanks - will do this tonight as well..... The oil is all nice and new as well.....

New water-pump, with seals - correct facing direction as well - new drive gears too - pump works correctly, i stripped the cover off and bumped the motor to confirm they are turning.

 :thumleft:  I have seen a few pumps where the seals were fitted the wrong way around.  The working sides of these seals need to both face outward.  If the outer one is the wrong way around it will result in coolant slowly bleeding into the sump as the pressure in the cooling system builds.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 20, 2019, 07:19:45 am
:thumleft:  I have seen a few pumps where the seals were fitted the wrong way around.  The working sides of these seals need to both face outward.  If the outer one is the wrong way around it will result in coolant slowly bleeding into the sump as the pressure in the cooling system builds.

I imagine it would - and I reckon it would be noticeable if 190ml of coolant found its way into the sump - but the seals are definitely in the correct way - there is a note in the installation manual about this irrc, anyway I remember wondering about this and did some research at the time as to the why of it.

Drained some oil out of the sump last night - as you can see, there isnt any coolant in that!

My current bet is on either a pin-hole in a hose, or a leaky hoseclamp........

Keep ideas coming, I appreciate the input, and there has been thoughts posted that I didnt have, so thank you!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: dirt rat on March 20, 2019, 08:48:25 am
Check the hose on the bottom of the radiator- if the exhaust header is not correctly installed it can touch the hose at the bend and burn it.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 20, 2019, 08:54:03 am
Check the hose on the bottom of the radiator- if the exhaust header is not correctly installed it can touch the hose at the bend and burn it.

It is very close, isnt it? I will check again to be sure, certainly!

The clutch cable was incorrectly routed prior to my getting the bike and scorched the cover somewhat - not critically though.

Ran out of time last night to refill the coolant accurately, and rather than rush it and guess, i decided to leave it for tonight.....

Tomorrow I will ride again!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: katana on March 24, 2019, 09:20:04 pm
I am not sure if it was mentioned, but have you replaced the radiator cap?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 25, 2019, 07:21:27 am
I am not sure if it was mentioned, but have you replaced the radiator cap?

Yup - did that, as well as the seal and the thermostat....

Anyway, rode 10km yesterday before it started leaking water from the overflow....

So, Justin at Motorradtech is getting a call just now.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 25, 2019, 09:52:47 am
Right - after a short 10km ride yesterday, the problem is still prevailing....

So, after a chat with Justin at MotorradTech a few minutes ago - he has offered a exceptionally possible explination - and that is that there is blow-by on the water-jacket at the exhaust valve area, as a result of the head having a microscopic bulge as a result of overheating.....

This would also explain why the coolant is looking "milky" after 85km of riding - its getting pressurised fuel/exhaust fumes pushed into it.....

Now, i did have the head checked originally, and it was found to be OK, so it wasnt skimmed - live & learn I suppose hey?

Anyway - head is coming off tonight.....

Wish me luck!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Piet on March 25, 2019, 10:44:54 am


Wish me luck!!
Good luck! ;)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ktmmer on March 25, 2019, 10:45:57 am
Silverton radiators can do a test where they can ascertain whether exhaust gas enters your cooling system.

Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 25, 2019, 12:28:52 pm
Silverton radiators can do a test where they can ascertain whether exhaust gas enters your cooling system.

Thanks - I will ask them about this too - will post results here!

I just got back from MotorradTech, Justin is pretty confident this is the issue, he showed me another barrel & head of a bike that he has at his shop currently with the same problem.....

If this sorts the problem, I am happy.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: katana on March 26, 2019, 01:09:09 pm
I had a warped head on my Rotax powered Pegasso a number of times, but they thinned the head out when they fitted 5 valves in there.  Same symptoms though.  I think you might be on to something.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 26, 2019, 10:12:38 pm
@katana yes he has. Start the bike and ride it a little bit then put on stand and play with your hose :D 's and wipe it off. Might have a stress fracture. Are those hoses new or used? Are the clamps new or used? Are the hoses placed onto connectors far enough? Are you using the right hose clamps? Are the hoses original or aftermarket?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 27, 2019, 07:43:35 am
@katana yes he has. Start the bike and ride it a little bit then put on stand and play with your hose :D 's and wipe it off. Might have a stress fracture. Are those hoses new or used? Are the clamps new or used? Are the hoses placed onto connectors far enough? Are you using the right hose clamps? Are the hoses original or aftermarket?

Cheers - yes, we went through this process, @Halfdaft and I for about 4 hours last Saturday - the coolant is definitely "leaving" when the engine is under stress ie: when its being ridden (not hard, just up & down the road a couple of times will do it) - it does not happen when its idling on the bench.....
Hoses - we prodded, pulled & wiggled them - they are all in good condition, nice & flexible and have no build-up inside them - used torches to examine for leaks/splits etc.
Clamps - mostly new, some re-used hose clamps, situated correctly and tightened properly - no leaks around he end of the hoses.
Rad has been cleaned of scale, but according to Silverton it wasnt necessary as the rad was pretty clean anyway.

The most probable cause is a warped head, as far as I can tell - we have checked, re-checked & triple-checked everything else for hours!

Off to Silverton later this morning to see about checking the coolant for fuel contamination.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 27, 2019, 11:01:29 am
They need to have the bike running to check the gas levels in the coolant - and as this only happens when the bike is actually being ridden, under "load" and not static on a bench. this isnt going to work - but they were certainly able to advise that the pressure being created in the radiator was 99% likely to be caused by a leaky head-gasket - so this is the route we are going down...

Blitsie as of last night - back on the bench.....

Title: Re: The Story Of The Resurrection of Blitsie….
Post by: LoopSoosStroop on March 27, 2019, 11:23:44 am
For what it's worth, when my Forester leaked between the combustion chamber and water jackets a fine grey residue could be seen floating in the coolant and at the top of the overflow bottle. Looks almost like flat ash flakes. None of that visible? Maybe because I did a lot of km's like that and it gave it time to form.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: raffie on March 27, 2019, 11:30:48 am
CT, the gas check method is very subjective, and often gives a false no fault return.

An old, easy DIY and very reliable trick I use to check head gaskets, is to force compressed air into the cylinder while the engine is at TDC firing stroke. So piston TDC and all valves closed.
If the gasket is blown, even very slightly, air will be forced past the "blow" into the cooling system, displacing a bit of coolant. If the head gasket is blown, coolant will be forced out at the radiator / filler neck. If the "blow" is very slight, the level at the radiator neck will rise / overflow very slowly, leave the pressure on the cylinder for a few minutes, to be sure.

It can be a bit tricky to get it exactly TDC, so try to allow the compressed air into the cylinder gradually, as if the engine is not 100% TDC the compressed air will spin it. Don't leave the tool used to turn the engine on the bolt.....

Fill the radiator to the brim, its best if the system is bled properly as well.
I use a made up pipe with a modified compression tester fitting to force 8 bar into the cylinder.

If the engine is hot when doing the test, the level may drop slightly as it cools.

Hope this make sense... :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 27, 2019, 11:40:40 am
CT, the gas check method is very subjective, and often gives a false no fault return.

An old, easy DIY and very reliable trick I use to check head gaskets, is to force compressed air into the cylinder while the engine is at TDC firing stroke. So piston TDC and all valves closed.
If the gasket is blown, even very slightly, air will be forced past the "blow" into the cooling system, displacing a bit of coolant. If the head gasket is blown, coolant will be forced out at the radiator / filler neck. If the "blow" is very slight, the level at the radiator neck will rise / overflow very slowly, leave the pressure on the cylinder for a few minutes, to be sure.

It can be a bit tricky to get it exactly TDC, so try to allow the compressed air into the cylinder gradually, as if the engine is not 100% TDC the compressed air will spin it. Don't leave the tool used to turn the engine on the bolt.....

Fill the radiator to the brim, its best if the system is bled properly as well.
I use a made up pipe with a modified compression tester fitting to force 8 bar into the cylinder.

If the engine is hot when doing the test, the level may drop slightly as it cools.

Hope this make sense... :thumleft:

makes perfect sense - and I will see if I can make up something to screw into the spark-plug hole to do this - a good call.

TDC on the Rotax motor is dead easy - there is a bolt-hole at the bottom of the engine casing, once removed and the motor is at TDC, there is a slot in the crank that a pointed bolt fits into and locks the crank in place - so no movement and you know that its exactly TDC to set the cam-chain sprockets.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 27, 2019, 11:48:45 am
For what it's worth, when my Forester leaked between the combustion chamber and water jackets a fine grey residue could be seen floating in the coolant and at the top of the overflow bottle. Looks almost like flat ash flakes. None of that visible? Maybe because I did a lot of km's like that and it gave it time to form.

Nothing visible - but then I have only put around 80km on the bike so far - a little over 2 hours riding.
The one thing is that the coolant seems to me to be a little "milky" when compared to fresh coolant, like its a little opaque - initially i assumed this was just calcification coming off the inside of the motor, but now i am leaning towards exhaust/compression gasses mixing in with the coolant......
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on March 27, 2019, 11:53:41 am
Ai toggie broer, dat jy so moet sukkel! At least you are getting to the bottom of the initial problem.

And I felt despondent when the CRF230F I partly stripped, greased and rebuilt overflows petrol from the carburettor...
I just have to take off the carb and reset the float - I should be lucky...
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on March 27, 2019, 12:50:23 pm
Ai toggie broer, dat jy so moet sukkel! At least you are getting to the bottom of the initial problem.

And I felt despondent when the CRF230F I partly stripped, greased and rebuilt overflows petrol from the carburettor...
I just have to take off the carb and reset the float - I should be lucky...

yes indeed - it is a sukkel, but tbh, I dont actually mind, as when its sorted, its sorted, and I will have gained a wealth of knowledge that may or may not be useful in the future! I was under no illusions when I started this, but the reward of riding it, even for only 80km, has been a wonderful payoff - the bike is brilliant! Its so light and nimble and easy to use on the tight & twisty single-tracks - I really need to sell the GSA so that I can keep this!

The 2nd aspect is that there are a few niggles that I discovered when riding, that I want to sort out, so if he bike is in pieces, I will get those done at the same time - all small, non-critical things, but stuff i want done.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on March 27, 2019, 01:40:07 pm
 :). So you are still enjoying it.  As much as we enjoy reading and learning from your project :thumleft:

Yes, there is a case to be made for light bikes. I rode a 403kg Harley Davidson cruiser and could hardly keep it upright. Is an adventure bike approaching 300kg still an adventure bike? If you have ridden a GSA in strange places, a blitsie becomes a gift from heaven!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on March 29, 2019, 05:09:16 pm
@ClimbingTurtle I take it you had the engine apart, have you maybe not properly installed the head gasket? Did you sand both mating surfaces clean and checked the gasket itself before installing as the gaskets can get damaged in shipping. Also used bikes leave the coolant discolored as there is filth/corrosion in the system depending on age and mileage of the bike. But you did say you cleaned the system out. Generally if I rebuild a motorcycle I get the head engineered and is super cheap for the peace of mind and I know for a fact then that the head is perfect before installing. If you are taking the head off check the gasket and both mating surfaces you will see blow by if the gasket has failed or did not properly seal. If you are going to send the head in send the block housing in also with so they both can be decked flat, but you will need a thicker gasket after that as to keep to stock values. But first make sure that this is the issue since this is a lot of PT and cost involved.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 01, 2019, 09:32:16 am
@ClimbingTurtle I take it you had the engine apart, have you maybe not properly installed the head gasket? Did you sand both mating surfaces clean and checked the gasket itself before installing as the gaskets can get damaged in shipping. Also used bikes leave the coolant discolored as there is filth/corrosion in the system depending on age and mileage of the bike. But you did say you cleaned the system out. Generally if I rebuild a motorcycle I get the head engineered and is super cheap for the peace of mind and I know for a fact then that the head is perfect before installing. If you are taking the head off check the gasket and both mating surfaces you will see blow by if the gasket has failed or did not properly seal. If you are going to send the head in send the block housing in also with so they both can be decked flat, but you will need a thicker gasket after that as to keep to stock values. But first make sure that this is the issue since this is a lot of PT and cost involved.

I cleaned and sanded (P800 on a pane of glass) the mating surfaces when I originally assembled the motor - but I did whip the head & barrel off yesterday anyway as we are running out of options - results will follow in pictorial format, but i do think there is blow-by on the narrow band between the barrel & the water-jacket, so i ma getting it machined, both the barrel & the head....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on April 01, 2019, 09:44:32 am
I cleaned and sanded (P800 on a pane of glass)

I have rarely seen that work!  People do not realize how flexible glass is.  It would basically boil down to how flat the surface was that the glass was on.  Any pressure on the glass would have made it conform to whatever it was resting on.

If you used a piece of 50mm thick bullet proof glass you may have better success, but quite honestly, for the cost and time saving, get it skimmed professionally.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on April 01, 2019, 10:47:09 am
I'd have agree with jughead on this. This would only work perfectly on certified AAA flat lab Granite used for hand scraping on machinery. Only then would would there be no deflection of the glass when you put pressure on it. By to that extent might as well just send in the head and block. Getting those 2 machined on motorcycles is relatively cheap since the surface being done is small. Since you are sending them in check if you can get a thicker gasket otherwise you will push your values out of whack and can get higher compression or less cc's.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ktmmer on April 01, 2019, 10:57:08 am
I'd have agree with jughead on this. This would only work perfectly on certified AAA flat lab Granite used for hand scraping on machinery. Only then would would there be no deflection of the glass when you put pressure on it. By to that extent might as well just send in the head and block. Getting those 2 machined on motorcycles is relatively cheap since the surface being done is small. Since you are sending them in check if you can get a thicker gasket otherwise you will push your values out of whack and can get higher compression or less cc's.

Bore and Stroke remains unchanged so capacity remains the same , the compression will go up depending how much they take off. Often it is negligible.   
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 01, 2019, 11:30:24 am
In retrospect I should have just done it - but I was basically just cleaning the junk off of the head.
Penny-wise & Pound-foolish....  :biggrin:
Ah well, this is a learning curve too, so no harm, no foul...
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 01, 2019, 01:56:31 pm
So Blitsie is back on the bench in preparation of the open-engine surgery that we “think” is required to get the coolant to stay in the system…..
I will also be doing some upgrades and adding a few goodies during this process, may as well, seeing as he’s apart anyway, hey?
So, first thing, is Off with the Covers!! And the saddle…..
And drain coolant and oil…..

(https://i.postimg.cc/sxMbJz9x/PIC-9-1.jpg)

Off with the Air Box and disconnect and label all the wiring – just makes it easier to re-attach later.

(https://i.postimg.cc/wjXZ20JX/PIC-9-2.jpg)

(https://i.postimg.cc/bvqMBkHK/PIC-9-3.jpg)

Head-cover off, set motor to TDC and lock with genius locking bolt….

(https://i.postimg.cc/dVPgGz7Q/PIC-9-4.jpg)

Cam’s off – re-check the valve clearance first, all within spec.
Time to remove the head…..

(https://i.postimg.cc/zXR9bJGP/PIC-9-5.jpg)

(https://i.postimg.cc/HWNqkJdy/PIC-9-6.jpg)

Now, with the head off, and cleaned of oil etc., we can see 2 potential issues…
1 – the red arrow shows the area where the blow-by is expected to occur, closest to the exhaust valves – and there is a little brown ridge visible, I suspect this is the problem…. That would be where the exhaust gasses enter the coolant chamber, causing additional pressure build-up and the explusion of the coolant via the overflow.
2 – Not sure if this is an issue or not – there are no cut-outs on the gasket for the water-chabers marked in blue, apart from the one vent-hole marked in green – anyone want to comment here please, any input is appreciated!!

(https://i.postimg.cc/jjv902MC/PIC-9-7-LI.jpg)

(https://i.postimg.cc/ZRRQTmQH/PIC-9-8.jpg)

Head & Barrel is going off to Cava Engineering in Jhb as soon as I can get a gap to take it – and I don’t have to remove the valves to get it skimmed either…..
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on April 01, 2019, 02:58:08 pm
@ClimbingTurtle Better hope this fixes it and it's not a crack in the engine cooling passages. Lets just hold thumbs and wish. This all is super PT that you have gone through. Those pesky motorcycle gremlins always looking for trouble.
Also based on the gasket it's correct here's a photo from motoworks UK website on the x-challenge head gasket.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 01, 2019, 03:22:47 pm
@ClimbingTurtle Better hope this fixes it and it's not a crack in the engine cooling passages. Lets just hold thumbs and wish. This all is super PT that you have gone through. Those pesky motorcycle gremlins always looking for trouble.
Also based on the gasket it's correct here's a photo from motoworks UK website on the x-challenge head gasket.

 :o

I think this is the answer... I hope so anyway!

That gasket pic is exactly the same as the gasket I have - only mine is upside down (depending if you are looking from the top or bottom of course) - My pic the gasket and head are upside down, so your pic would be correct from the top - the holes are the same, so it must be correct! Mine was original OEM part from AutoAlpina....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on April 01, 2019, 03:56:48 pm
So hopefully the gasket is not damaged? Wonder if it is worth the while to fit a new one. Are there marks on the old new gasket? You might not see marks, but pressure might have caused some damage?
I don't know, just asking.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ktmmer on April 01, 2019, 05:01:53 pm
Dont crucify me , but some copper gasket spray might do the trick. Even if you are using a new gasket.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on April 01, 2019, 08:31:02 pm
So hopefully the gasket is not damaged? Wonder if it is worth the while to fit a new one. Are there marks on the old new gasket? You might not see marks, but pressure might have caused some damage?
I don't know, just asking.

That's the head gasket.  A new one will be required regardless of whether the old one is damaged.  Head gaskets are once off use items.  Once it has been compressed, it cannot be removed and reused.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 02, 2019, 07:26:19 am
So hopefully the gasket is not damaged? Wonder if it is worth the while to fit a new one. Are there marks on the old new gasket? You might not see marks, but pressure might have caused some damage?
I don't know, just asking.

That's the head gasket.  A new one will be required regardless of whether the old one is damaged.  Head gaskets are once off use items.  Once it has been compressed, it cannot be removed and reused.

Correct - installing a new head & base gasket as a matter of course, seeing as the head & barrel are going in for machining, it would be silly not to replace those as well, the base gasket I "may" have taken a chance on, but the one corner tore when I removed it, so no option there, but thats a cheap one, around R120 - head gasket is R650.......
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on April 02, 2019, 07:47:29 am

Correct - installing a new head & base gasket as a matter of course, seeing as the head & barrel are going in for machining, it would be silly not to replace those as well, the base gasket I "may" have taken a chance on, but the one corner tore when I removed it, so no option there, but thats a cheap one, around R120 - head gasket is R650.......

@ClimbingTurtle, that head gasket is correct.  It has been designed like that by pimply nerds with white coats, thick glasses and many pens to force coolant circulation around the barrel.  Otherwise the coolant will just go in one side and out the same side, or pretty close to where it went in, leaving the remainder of the cylinder much hotter than it is designed to be.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 02, 2019, 08:41:01 am

Correct - installing a new head & base gasket as a matter of course, seeing as the head & barrel are going in for machining, it would be silly not to replace those as well, the base gasket I "may" have taken a chance on, but the one corner tore when I removed it, so no option there, but thats a cheap one, around R120 - head gasket is R650.......

@ClimbingTurtle, that head gasket is correct.  It has been designed like that by pimply nerds with white coats, thick glasses and many pens to force coolant circulation around the barrel.  Otherwise the coolant will just go in one side and out the same side, or pretty close to where it went in, leaving the remainder of the cylinder much hotter than it is designed to be.

Cheers - I knew it was the correct part number, and they have all been the same (3 so far)  :biggrin: - but as I am not the white-coated, many pens (i do have the glasses, albeit not thick) techie, I thought a question would be better than chopping up a perfectly good gasket.....  :)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Sandvreter on April 02, 2019, 03:36:13 pm
@ClimbingTurtle : Man you are getting good with this.
Thanks for posting all the pics and taking the time to write it up.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on April 02, 2019, 05:39:46 pm
If 1 is a sign of leakage, 2 and 3 are on their way as well...
Just as well you are skimming.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 03, 2019, 07:40:32 am
If 1 is a sign of leakage, 2 and 3 are on their way as well...
Just as well you are skimming.

No - the area that is in question is at the tip of the red arrow below - there is a thin black line running between the barrel cavity and the water-jacket - that is where the blow-by is potentially happening. That brown mark is the burn on the top of the chamber, it actually just rubs off. But yes, it needs to be skimmed - just need a gap to get it to Cava.......
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: LegoBrew on April 03, 2019, 09:15:22 am
Would it help to build up that area before machining it?

Seems like a recurring future issue to me?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on April 03, 2019, 09:51:34 am
If 1 is a sign of leakage, 2 and 3 are on their way as well...

The area of concern is that between the green and blue circles, and yes @ClimbingTurtle, it certainly looks as though you had an issue around the area you indicate.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 03, 2019, 10:38:31 am
Would it help to build up that area before machining it?

Seems like a recurring future issue to me?

Not a recurring issue, but a known one - that area I indicated is pretty narrow, and if the motor overheats in an extreme (no coolant) - it tends to "bulge" up/down and creates a very small, microscopic gap that allows compression gasses into the coolant channels - (incidently, this only happens when the motor is under load, not iddling on the bench, so not easy to spot...) I spoke to Justin at MotorradTech about it, he knows of a few cases, it is fixable in this case, but he showed me a head that was completely shot, you could actually seethe warp with the naked eye..... The overheating is the issue....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 03, 2019, 10:41:05 am
If 1 is a sign of leakage, 2 and 3 are on their way as well...

The area of concern is that between the green and blue circles, and yes @ClimbingTurtle, it certainly looks as though you had an issue around the area you indicate.

Exactly that ring @Jughead - we believe a very light skim on both the head & barrel will sort this out, clean up the mating surfaces properly etc.
BUT it did require the head to come off to see it - very little indication (other that the experience of others) otherwise....

My other issue is that work is actually keeping me busy and away from getting the head to the machine shop.....  >:(
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on April 03, 2019, 11:03:06 am
Disclaimer - I sell them!:
Wonder if a BoosterPlug will help preventing the problem?
These engines run lean (towards 14,7:1) to comply with Euro 4 regulations, increasing combustion chamber temperatures, and giving rise to all kinds of problems. The air cooled R1200's are known lean runners, and they temporarily seize because of heat (the pistons expand so that they start rubbing against the piston sleeves, with the pistons becoming physically smaller). A distinct piston knock when starting up is a tell tale. BoosterPlug adds 6% petrol under load (acceleration), deceleration and idle, (in open loop, whenever there is a change in rpm or TPS) and makes the engine run cooler (it solves the pinking issue on the 1200 air cooled motors and others). More petrol cools down the combustion process. I have had many reports of e.g. KTM 1190s running cooler and the cooling fan not activating as quickly. In Blitsie's case it will reduce combustion chamber heat. It might have helped to prevent overheating in the first place...
On the side: feedback from 650 riders are that the bike goes much better with one installed.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 03, 2019, 11:25:06 am
Disclaimer - I sell them!:
Wonder if a BoosterPlug will help preventing the problem?
These engines run lean (towards 14,7:1) to comply with Euro 4 regulations, increasing combustion chamber temperatures, and giving rise to all kinds of problems. The air cooled R1200's are known lean runners, and they temporarily seize because of heat (the pistons expand so that they start rubbing against the piston sleeves, with the pistons becoming physically smaller). A distinct piston knock when starting up is a tell tale. BoosterPlug adds 6% petrol under load (acceleration), deceleration and idle, (in open loop, whenever there is a change in rpm or TPS) and makes the engine run cooler (it solves the pinking issue on the 1200 air cooled motors and others). More petrol cools down the combustion process. I have had many reports of e.g. KTM 1190s running cooler and the cooling fan not activating as quickly. In Blitsie's case it will reduce combustion chamber heat. It might have helped to prevent overheating in the first place...
On the side: feedback from 650 riders are that the bike goes much better with one installed.

Worth a look at the very least?
Send me a price?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on April 03, 2019, 11:52:37 am
Disclaimer - I sell them!:
Wonder if a BoosterPlug will help preventing the problem?
These engines run lean (towards 14,7:1) to comply with Euro 4 regulations, increasing combustion chamber temperatures, and giving rise to all kinds of problems. The air cooled R1200's are known lean runners, and they temporarily seize because of heat (the pistons expand so that they start rubbing against the piston sleeves, with the pistons becoming physically smaller). A distinct piston knock when starting up is a tell tale. BoosterPlug adds 6% petrol under load (acceleration), deceleration and idle, (in open loop, whenever there is a change in rpm or TPS) and makes the engine run cooler (it solves the pinking issue on the 1200 air cooled motors and others). More petrol cools down the combustion process. I have had many reports of e.g. KTM 1190s running cooler and the cooling fan not activating as quickly. In Blitsie's case it will reduce combustion chamber heat. It might have helped to prevent overheating in the first place...
On the side: feedback from 650 riders are that the bike goes much better with one installed.

A Boosterplug will most certainly not prevent a motor overheating due to loss of coolant. And loss of coolant is the only thing that makes these motors overheat.

I have yet to see an R1200 "temporarily sieze" because of heat, even in the Karoo at 40+ temperatures.. 

The pinging issue on the twincam engines is purely a cam adjustment issue.  I have resolved numerous pinging twincams by just aligning the cams correctly.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on April 03, 2019, 02:21:10 pm
Disclaimer - I sell them!:
Wonder if a BoosterPlug will help preventing the problem?
These engines run lean (towards 14,7:1) to comply with Euro 4 regulations, increasing combustion chamber temperatures, and giving rise to all kinds of problems. The air cooled R1200's are known lean runners, and they temporarily seize because of heat (the pistons expand so that they start rubbing against the piston sleeves, with the pistons becoming physically smaller). A distinct piston knock when starting up is a tell tale. BoosterPlug adds 6% petrol under load (acceleration), deceleration and idle, (in open loop, whenever there is a change in rpm or TPS) and makes the engine run cooler (it solves the pinking issue on the 1200 air cooled motors and others). More petrol cools down the combustion process. I have had many reports of e.g. KTM 1190s running cooler and the cooling fan not activating as quickly. In Blitsie's case it will reduce combustion chamber heat. It might have helped to prevent overheating in the first place...
On the side: feedback from 650 riders are that the bike goes much better with one installed.

A Boosterplug will most certainly not prevent a motor overheating due to loss of coolant. And loss of coolant is the only thing that makes these motors overheat.


Indeed, but take one step back. Running cooler might prevent warping (that causes blow past) in the first place. Extreme temperatures cause warping, and if it is a common problem on these engines, preventative steps should be best?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 03, 2019, 02:41:50 pm
Indeed, but take one step back. Running cooler might prevent warping (that causes blow past) in the first place. Extreme temperatures cause warping, and if it is a common problem on these engines, preventative steps should be best?

Not common - lets not go that far, but it is a known result of overheating due to coolant loss - they generally don't overheat like this, this motor was run hard and dry I believe (and I don't know the circumstances, so I am guessing) - also the rad on the X is quite small (not sure about the other 650 single BM's) compared to the XR650L for example, a contributing factor, but its not a common problem, far from it..... ! I am still interested in it though...

And my 1200 also had the "Ping" at the beginning, had the cams set and zero problems after that - even in 47deg Northern Namibia. I, on the other hand, nearly died..... No, really, I did - heatstroke......  :imaposer:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on April 03, 2019, 02:44:34 pm
Indeed, but take one step back. Running cooler might prevent warping (that causes blow past) in the first place. Extreme temperatures cause warping, and if it is a common problem on these engines, preventative steps should be best?

No, 70% of the overheating on these motors is caused by a pebble or something similar getting caught between the frame and the radiator which punctures it and it then pisses the coolant out.

The other 30% is either buggered waterpump seals, buggered waterpump impeller gears or just plain lack of maintenance.  I have one client in Namibia that has put, at the last service, 161000km on his 2000 Dakar, all without a boosterplug, and without overheating once.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 03, 2019, 03:30:16 pm
@Jughead - for interest, do you have a F650 radiator handy to measure the size of the core (between the side sections) so just the cooling section, length & height, purely to see what the difference in size is to the Gx?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Mad777max on April 03, 2019, 04:35:27 pm
they're not very big either on the Dakar. In summer it also runs quite warm. but doesn't overheat luckily.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on April 03, 2019, 08:56:35 pm
@Jughead - for interest, do you have a F650 radiator handy to measure the size of the core (between the side sections) so just the cooling section, length & height, purely to see what the difference in size is to the Gx?

Will do for you in the morning.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on April 04, 2019, 08:19:51 am
@Jughead - for interest, do you have a F650 radiator handy to measure the size of the core (between the side sections) so just the cooling section, length & height, purely to see what the difference in size is to the Gx?

Here you go. 

1 - Length from inside the endcap.
2 - Height
3 - Width

The marks in the second photo alongside the tape measure is what I was referring to in my earlier post.  This was a pebble that was kicked up by the front wheel, which then gets caught between the frame and the radiator.  All 7 of those tubes are punctured.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 04, 2019, 09:48:46 am
Thanks Jughead - that is the same size as Gx as far as I can tell - gives me a couple of options going forward.
The Gx also sits pretty close to the frame, but the rad is in-front of the frame, plastic fin/covers protecting it, but it does get mud clogging it pretty easily!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on April 05, 2019, 01:25:07 pm
@ClimbingTurtle First get it running properly without overheating because of coolant issues. Want to at least use the bike normally and not blow up :P . But just think after all this work how great the bike would run then.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 08, 2019, 09:59:41 am
@ClimbingTurtle First get it running properly without overheating because of coolant issues. Want to at least use the bike normally and not blow up :P . But just think after all this work how great the bike would run then.
Yes indeed - that is the plan currently - and the 80km or so i have ridden have been mighty fine - its a great ride!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 09, 2019, 03:55:47 pm
Head & Barrel are back.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: LoopSoosStroop on April 10, 2019, 08:24:58 am
Steve, did you strip the valves off before taking for skimming?

I once did not do that with a head and when it came back I luckily removed one valve before re-assembling the motor. The amount of grit and swarf that came out from under the valve springs and bucket was frightening. I suppose it got in there when the place "cleaned" the head.

Anyhow, lesson learnt. Took everything apart again and cleaned properly.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 10, 2019, 08:41:40 am
Steve, did you strip the valves off before taking for skimming?

I once did not do that with a head and when it came back I luckily removed one valve before re-assembling the motor. The amount of grit and swarf that came out from under the valve springs and bucket was frightening. I suppose it got in there when the place "cleaned" the head.

Anyhow, lesson learnt. Took everything apart again and cleaned properly.

I did not - they advised it was not necessary - but I was planning to take the cup-washer clips out and push the valves down (open) to wash them out with a spray-bottle of paraffin, just to be safe - but thanks for the thought, always better to make sure I haven't missed something, input is valued!!

Sad story is that I wont get to do any work until probably Monday next week - heading to Loskop Dam on Friday morning at Sparrows for the "Wild Challenge" - 1/2-marathon on Saturday..... Why do I do this....?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on April 10, 2019, 12:58:05 pm
Do you have to fit a thicker gasket to compensate for the skimming, or was it so little that it will not make a difference? Especially since both mating surfaces were skimmed?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 10, 2019, 01:23:12 pm
Do you have to fit a thicker gasket to compensate for the skimming, or was it so little that it will not make a difference? Especially since both mating surfaces were skimmed?

Standard gasket - it was a minimal amount - wont have a noticeable impact on the compression.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 18, 2019, 10:45:29 am
Not much progress this last while, been away at Loskop for the half-marathon last weekend, but managed to clean the head up, spray it out with paraffin after removing the valves - not much grinding dust in there, but always better to be safe at this level!!

(https://i.postimg.cc/RZ5sQ3DW/PIC-10-1.jpg)

(https://i.postimg.cc/2y1cTnYZ/PIC-10-2.jpg)

Also had some new bar-ends made, as well as a few bushes & stuff that I needed done to hold the oil tank, and the liner bushes for the fuel tank supports.

(https://i.postimg.cc/jSH88spZ/PIC-10-3.jpg)

(https://i.postimg.cc/zfqx6s55/PIC-10-4.jpg)

Also started the design for the rear fender supports - mine are cracked, so I will have some laser cut from Alu plate - 1.6mm - and drill them next week

(https://i.postimg.cc/d0n5Y5tC/PIC-10-5.jpg)

More interesting things will happen soon - looking at a bracket to mount the Scotts Damper, as well as a fuel solution.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on April 18, 2019, 04:20:06 pm
@ClimbingTurtle Ah finally see you got the head skimmed. Hope this solves the issue otherwise you going to blow your own head gasket hehe. If it's fixed and all good gimme a pm i'm also in Gauteng so can go and burn some fuel.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 23, 2019, 11:15:32 am
So, roll on Easter Weekend, Friday involves a quick trip to @Halfdaft to grab some of this fine oil, he sold me a bottle as I could not find any on the East Rand (Well, not at less than R750 for 4-litres)

(https://i.postimg.cc/wjx7Vwwv/PIC-10-6.jpg)

and back home - barrel on with a new base gasket, sikkled a bit, took it slow & steady, added a new hose as well, precautionary, you understand, as the other had a scorch mark on ....

(https://i.postimg.cc/0jpbtFg6/PIC-10-7.jpg)

Add the skimmed head, torque it doen in the correct order, put in the bolts that hold the head onto the top frame, tork them to 74Nm and.......

(https://i.postimg.cc/3JTyy8p2/PIC-10-8.jpg)

FFS!!!! the donerse M10 bolt has sheared off in the head......  :-\ Fork. Step away from the tools, slowly mind, get a chair and stop myself from throwing up..... Is this bike going to fight me the WHOLE WAY?????
WhatsApp Halfdaft, we discuss the options which are:-
a) Just leave it and carry on regardless...... Downside here is that the Rear shock mount locates on the back of the head, so if it flexes, it could potentially crack parts of the head....
b) Take the head off and try and get it out of the top of the frame - The chances of success are slim, as the sheared bolt is sticking out into the frame, so I cant slide it up & out - the upside is that there is some sheared bolt and there MIGHT be enough to grip with a vice-grip to get it out. Downside is that I will have to replace ANOTHER R600 head gasket.....  :'(
c) - Take the entire engine out and work on it on its side. Downside is that its still going to be difficult getting the head section out of the frame, and to take the motor out you have to remove the rear swingarm - moerse pain in the arse..... Upside is that a new head-gasket is not required......

What to do.........

After discussion, option b) is going to be the most viable......
But as Saturday was already dedicated to home-affairs, and I had a somewhat epic hangover, I only approached the Blitsie after lunch.......
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ChrisL - DUSTRIDERS on April 23, 2019, 11:20:06 am
My heart bleeds for you, you're a better man than me I would have given up long time ago. :deal: :(
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on April 23, 2019, 11:22:58 am
Eish...
B will allow you to weld another bolt on and take the broken one out,  drill it out, or as you say, screw it out as the bolt is not under tension any more.
Hou moed, you will get there soon! :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 23, 2019, 01:02:29 pm
After a moments reflection, because this is somewhat akin to a pilgrimage, I started looking at what needed to be done to remove the head, broken bolt in-situ, and realized that I could potentially spread the 2 arms of the frame to get the head out, I only need 5mm, maybe less....
Best way to do that is to loosen off all the lower frame arms and rear swingarm mounts to allow some "play" in the system, so first step is to remove the rear subframe, so that I can access the rear shock top mount, unbolt the top and swing the support bracket out of the way.... THEN remove all the torqued head bolts and get it ready for removal....

(https://i.postimg.cc/RZPqbwYT/PIC_10.9.jpg)

That took a while as I wanted to make sure I was getting the correct bits out in order... And then i grabbed a bottle jack, made up a quick support jig, and started pomping, and.....Nothing..... Mainly because I forgot to close the bleed screw on the jack...  :biggrin: Anyway, closed screw, slowly jacked the frame arms apart.....

(https://i.postimg.cc/k5zG7qq6/PIC_11.0.jpg)

And SUCCESS!! there was just enough room  to slide the head out, complete with broken bolt!

(https://i.postimg.cc/QxJF12kw/PIC_11.1.jpg)

As you can see, there isnt enough to grab onto, but what I did manage to do, was drill a small flat onto the end, whilst it was still in the frame, using the adjuster as a guide - this would go some way in helping us out later....

Sunday morning I was off to @Halfdaft on the 1200, head tucked away safely in the top-box.....
After I got there, and inspection was completed, he whipped out the Bosch cordless drill and what I remember as a small Left-Hand drill bit, and proceeds to try and drill the broken stud, to get a hole to use an Eezi-Out - and while he is drilling, the bot actually starts un-turning itself!!! Well, a little bit anyway, so Eez-Out on, and bolt out, dress the helicoil, i load up and off home again - I am seriously pleased with my day so far!!

(https://i.postimg.cc/pV8hXh92/PIC_11.2.jpg)

The offending broken cap-screw....

(https://i.postimg.cc/8Cjs8jQg/PIC_11.3.jpg)

At this point i decided to use the head-gasket i had just put in, based on the fact that the bike hadnt even run with it in yet, and BMW is closed for another 2 days.....
I continued with the slow & methodical assembly, head, valve tappets, cover, rear spring & mount, airbox...

(https://i.postimg.cc/gJhJJQ2M/PIC_11.5.jpg)

And then the rear sub-frame, including the fuel tank, rear fender etc..... And as I bolt in the long M8 mounting bolt (I replaced the 2 short ones, right at the beginning...) and the bolt strips....... I DESPAIR, I feel I may be cursed,or Blitsie is, or both..... BUT, I know I can get one on Tuesday at any rate......

(https://i.postimg.cc/C5HxC8Dk/PIC_11.6.jpg)

Funny thing is, the Steel thread was screwed into Alu, and the thread in the Alu is not damaged, but the threaded steel capscrew.....  :eek7:

(https://i.postimg.cc/BZxbfryb/PIC_11.7.jpg)

All was not lost though - after connecting everything back up, battery in, coolant & oil filled (And Spilled) he fired up after a couple of cranks, into a smooth idle.....
After running it up to temp, the fan kicked in & off again as required, so we know that is all working....
No signs of coolant or oil leaks, but then there wasnt last time either..... But in the absence of the rear sub-frame bolts, I will not attempt a ride for a day or 2!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: woody1 on April 23, 2019, 02:03:22 pm
I think the problem is with those surgical gloves.  Poor bike is just waiting for you to check the old prostate. :laughing4:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 23, 2019, 02:53:29 pm
I think the problem is with those surgical gloves.  Poor bike is just waiting for you to check the old prostate. :laughing4:

Proctology Gloves -  :thumleft:

I cut my thumb in the fight, trying to keep the k@k out of it - which didnt work anyway.....  :imaposer:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jughead on April 23, 2019, 03:28:57 pm
I think the problem is with those surgical gloves.  Poor bike is just waiting for you to check the old prostate. :laughing4:

Proctology Gloves -  :thumleft:

I cut my thumb in the fight, trying to keep the k@k out of it - which didnt work anyway.....  :imaposer:

I wear the black gloves like that.  But then I find my hands don't want to work!  :o
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ChrisL - DUSTRIDERS on April 23, 2019, 03:36:10 pm
I think the problem is with those surgical gloves.  Poor bike is just waiting for you to check the old prostate. :laughing4:

Proctology Gloves -  :thumleft:

I cut my thumb in the fight, trying to keep the k@k out of it - which didnt work anyway.....  :imaposer:

I wear the black gloves like that.  But then I find my hands don't want to work!  :o
:spitcoffee: :spitcoffee: :lol8:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on April 23, 2019, 03:38:41 pm
@ClimbingTurtle Did you reuse old head bolts? Never really good idea to reuse head bolts as they stretch once installed. This is probably why the bolt sheared off perhaps? But my hats off to you ,you've got the patience of a monk. I would have long time ago already lit the bike on fire!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 23, 2019, 03:43:28 pm
@ClimbingTurtle Did you reuse old head bolts? Never really good idea to reuse head bolts as they stretch once installed. This is probably why the bolt sheared off perhaps? But my hats off to you ,you've got the patience of a monk. I would have long time ago already lit the bike on fire!

No - re-used the bolts - the BMW manual doesnt specify that they need to be replaced (actually nuts, not bolts, the head bolts are studs), so I re-used them - they do make mention of what ones not to re-use, but this wasnt one of them.

This is actually a bolt that mounts the head to the frame, so not the head to the barrel.....

And I am too far in not to be patient - and I'm off to fetch the new cap-screw i need!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: BullFrog on April 23, 2019, 03:45:36 pm
And you STILL take the time to take pics!!!!!!

You are a special breed!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: GRUNT on April 23, 2019, 04:10:30 pm
This is my favourite thread at the moment, I come and have a look see everyday, to say that Blitsie is challenge( pun intended) is an understatement!
Hats off to you turtle, I can't wait for the first RR with this bike :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Ganjora on April 23, 2019, 06:12:29 pm
Unbelievable.
From a reader's point of view this is the thread that doesn't stop giving!
Good luck.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Edgar on April 23, 2019, 07:55:26 pm
Yes, this one is close to my heart.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Superkazy on April 23, 2019, 07:59:39 pm
@ClimbingTurtle Generally rule of thumb you want to replace nuts and bolts/studs that get loaded quite often this includes the suspension bolts from time to time stretch and snap and engine mount bolts etc. It's just a rule of thumb I use that saves me from having trouble in the future like you are experiencing now hehe. But luckily you got it out. Snapped bolts are a b****. Hopefully you can get the bike running in proper order soon.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Supervan on April 24, 2019, 09:00:12 am
I'm too scared to check the valve clearances on my XCountry. This thread (does this count as a pun?) makes me look bad  :'(
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 25, 2019, 08:37:54 am
HE RUNS!!

 :biggrin:

I went for a short 14km ride last night after replacing the sub-frame bolt - seems fine, no evidence of coolant dripping from the overflow pipe, although the overflow bottle seemed about 5mm short of coolant, but there are always the odd air-bubble in the system that needs to work its way out, no evidence of oil leaks either, which is rather nice!

This morning I checked the rad after leaving it to cool overnight, just about spot-on!! Yay!!

Tonight we wash him, and then the testing begins tomorrow....

Might need to check the valve gaps again, seems a little rattly for my liking.....

Roll on Sunday
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Black_Hawk on April 25, 2019, 09:11:12 am
Well done... hopelik het jy nou vir Blitsie gewys wie is baas en dat jy al sy geite nou uitgesorteer het. :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: caconcepts on April 25, 2019, 09:15:32 am
HE RUNS!!

 :biggrin:

I went for a short 14km ride last night after replacing the sub-frame bolt - seems fine, no evidence of coolant dripping from the overflow pipe, although the overflow bottle seemed about 5mm short of coolant, but there are always the odd air-bubble in the system that needs to work its way out, no evidence of oil leaks either, which is rather nice!

This morning I checked the rad after leaving it to cool overnight, just about spot-on!! Yay!!

Tonight we wash him, and then the testing begins tomorrow....

Might need to check the valve gaps again, seems a little rattly for my liking.....

Roll on Sunday

Nice job, I assume you are taking her to the playpen behind boat lake soon...... :ricky: :ricky: :ricky: :ricky: :ricky: :3some: :3some: :3some: :3some: :3some:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 25, 2019, 09:24:27 am
HE RUNS!!

 :biggrin:

I went for a short 14km ride last night after replacing the sub-frame bolt - seems fine, no evidence of coolant dripping from the overflow pipe, although the overflow bottle seemed about 5mm short of coolant, but there are always the odd air-bubble in the system that needs to work its way out, no evidence of oil leaks either, which is rather nice!

This morning I checked the rad after leaving it to cool overnight, just about spot-on!! Yay!!

Tonight we wash him, and then the testing begins tomorrow....

Might need to check the valve gaps again, seems a little rattly for my liking.....

Roll on Sunday

Nice job, I assume you are taking her to the playpen behind boat lake soon...... :ricky: :ricky: :ricky: :ricky: :ricky: :3some: :3some: :3some: :3some: :3some:

Yup - I wanted to pop up last night, but just ran out of light! Might be able to go after work today, or certainly tomorrow after work - I finish after lunch....  :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on April 25, 2019, 09:30:50 am
HE RUNS!!

 :biggrin:

I went for a short 14km ride last night after replacing the sub-frame bolt - seems fine, no evidence of coolant dripping from the overflow pipe, although the overflow bottle seemed about 5mm short of coolant, but there are always the odd air-bubble in the system that needs to work its way out, no evidence of oil leaks either, which is rather nice!

This morning I checked the rad after leaving it to cool overnight, just about spot-on!! Yay!!

Tonight we wash him, and then the testing begins tomorrow....

Might need to check the valve gaps again, seems a little rattly for my liking.....

Roll on Sunday

Yay!☺

Just one thing. Have you not considered changing Blitsie's gender from "he" to "SHE"? It just makes so much more sense...

I mean, the amount of time you spent on erm, it, some people might think you strange if it is a HE. if it is a she, no problem, because we know they need lots of tlc :peepwall:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 25, 2019, 09:40:56 am
HE RUNS!!

 :biggrin:

I went for a short 14km ride last night after replacing the sub-frame bolt - seems fine, no evidence of coolant dripping from the overflow pipe, although the overflow bottle seemed about 5mm short of coolant, but there are always the odd air-bubble in the system that needs to work its way out, no evidence of oil leaks either, which is rather nice!

This morning I checked the rad after leaving it to cool overnight, just about spot-on!! Yay!!

Tonight we wash him, and then the testing begins tomorrow....

Might need to check the valve gaps again, seems a little rattly for my liking.....

Roll on Sunday

Yay!☺

Just one thing. Have you not considered changing Blitsie's gender from "he" to "SHE"? It just makes so much more sense...

I mean, the amount of time you spent on erm, it, some people might think you strange if it is a HE. if it is a she, no problem, because we know they need lots of tlc :peepwall:

True This.
However @tankgirl is, well, a lady, and she named him Blitsie, so I am not sure of the protocol surrounding the renaming/re-sexing of a bike.....  :o
I believe a small weekend away ride to the hills of the Wolkberg Reserve, to further contemplate the change, to make fire, and drink beer, and to ride, not necessarily in that order....  :imaposer:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: GazGaz on April 26, 2019, 12:28:08 pm
Nice job on X I need a good workshop for my builds instead of getting someone else to do it
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Edgar on April 26, 2019, 03:32:40 pm
HE RUNS!!

 :biggrin:

I went for a short 14km ride last night after replacing the sub-frame bolt - seems fine, no evidence of coolant dripping from the overflow pipe, although the overflow bottle seemed about 5mm short of coolant, but there are always the odd air-bubble in the system that needs to work its way out, no evidence of oil leaks either, which is rather nice!

This morning I checked the rad after leaving it to cool overnight, just about spot-on!! Yay!!

Tonight we wash him, and then the testing begins tomorrow....

Might need to check the valve gaps again, seems a little rattly for my liking.....

Roll on Sunday

Yay!☺

Just one thing. Have you not considered changing Blitsie's gender from "he" to "SHE"? It just makes so much more sense...

I mean, the amount of time you spent on erm, it, some people might think you strange if it is a HE. if it is a she, no problem, because we know they need lots of tlc :peepwall:

True This.
However @tankgirl is, well, a lady, and she named him Blitsie, so I am not sure of the protocol surrounding the renaming/re-sexing of a bike.....  :o
I believe a small weekend away ride to the hills of the Wolkberg Reserve, to further contemplate the change, to make fire, and drink beer, and to ride, not necessarily in that order....  :imaposer:

Now that sounds lekker!!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 29, 2019, 09:51:33 am
So Saturday I decided to do some Speedy Upgrades at the last minute, I decided I wanted the GPS mounted and a power source, as we are testing Blitsie on Sunday morning, so I managed to whip these up from some off-cuts laying around.

(https://i.postimg.cc/8z1J7dgv/PIC.jpg)

Pity the GPS is in the way of my Speedo, but you cant win them all......  :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 29, 2019, 10:07:45 am
So Sunday we rode - met @Halfdaft at the R59N Blockhouse at a very reasonable 8am, and headed NW into the hills, dales, logging camps, tracks, mud and a mighty, mighty good time...

(https://i.postimg.cc/nLXLm0RX/KJLQ3740-Small.jpg)

(https://i.postimg.cc/kg14Dkcr/IMG-3187-Small.jpg)

 Blitsie performed well, but I had this niggling doubt.... SHE didnt start quite as easily, there was the odd backfire, seemed a little down on power, and there was a rattle at the top-end, like a loose rocker-arm or something, a loose tappet......  :P

Anyway, off home after a great ride - damn, I am unfit, I ache in places that shouldn't ache....., Anyway, after a pressure wash and a sponge bath, I checked fluids, found that they were low, so I had a beer. Blitsie was fine tho, coolant and oil PERFECT! That's a relief, we have solved the "Vanishing Coolant" mystery.....
s
So then I decided that I might have mis-timed the cams, maybe out by one tooth on the exhaust, or inlet perhaps? Ony one way to find out, whip the panels off, airbox off, injectors etc., and off with the valve covers.

First - check the cam-sprocket alignment at TDC - spot on, so thats not the problem....
Second, check the valce gaps.
Inlet - under 0.05mm, so spot on.
Outlet - one is 0.25mm, perfect. Other one is 0.95mm........ Now thats a problem.....  :o - WTF happened?

Remove the cams then, take the bucket of the one exhaust valve top and were the hell is the shim????? Vanished!! How does a shim vanish off the top of the valve spring cover, in a bucket, so a sealed area???? Thought process kicks in - go look in the discarded plastic bags, all neatly labeled, and....

(https://i.postimg.cc/L6kg4CwR/PIC_12.0.jpg)

How, in the name of all things motorcycle related, did that get left out??????

Long and short, replaced it - bucket was not damaged luckily - replaced all the bits - tap the starter button and she fires up first swing.....

So - more testing Wednesday!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Black_Hawk on April 29, 2019, 10:25:05 am
You are becoming a pro in fixing your bike, this is the best way to learn the "ins and outs" of the bike ;) 

Job well done :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Shaun500 on April 29, 2019, 04:32:49 pm
Just a question...did you rebore or hone the barrel? I stand under correction but I believe the BMW 650 barrel is nikasil plated.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Welsh on April 29, 2019, 05:05:56 pm
Ummm and you didn’t notice when you checked the valve clearances after fitting the cams?  :sip: just asking  :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 30, 2019, 07:23:25 am
Just a question...did you rebore or hone the barrel? I stand under correction but I believe the BMW 650 barrel is nikasil plated.

Correct - Nikasil coated - and we didn't bore it because it still had the original cross-hatching marks on it, and we also had it measured in a temperature controlled measuring room, x- and y-axis, top, middle & bottom of the barrel and it was all well within spec.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on April 30, 2019, 07:29:05 am
Ummm and you didn’t notice when you checked the valve clearances after fitting the cams?  :sip: just asking  :biggrin:

And I wondered if the question was going to be asked....  :imaposer:

I did measure, but before i took the cams off - theory being that there is no adjustment anyway, so if its measured before removal (manual recommends this) and then I reassembled them. I didn't check again after assembly - I mean why bother......  :eek7: and that's where the lesson was learned.....

I am very glad the bucket wasn't damaged!!!

But in all honesty, I should have worked out something was amiss when i tried to start it, it battled a bit, back-fired twice, and sounded like there was a tappet knock (which there was) - the only downside was a slight performance loss (one exhaust valve is opening late & closing early) and it just felt "off"
At that point i should have re-checked, but I was impatient......
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Shaun500 on April 30, 2019, 06:37:19 pm
Just a question...did you rebore or hone the barrel? I stand under correction but I believe the BMW 650 barrel is nikasil plated.

Correct - Nikasil coated - and we didn't bore it because it still had the original cross-hatching marks on it, and we also had it measured in a temperature controlled measuring room, x- and y-axis, top, middle & bottom of the barrel and it was all well within spec.
Ah ok that's interesting. My friend is quite into two strokes and told me there is only one place in JHB that does nicasil plating.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Welsh on April 30, 2019, 07:20:58 pm
Just a question...did you rebore or hone the barrel? I stand under correction but I believe the BMW 650 barrel is nikasil plated.

Correct - Nikasil coated - and we didn't bore it because it still had the original cross-hatching marks on it, and we also had it measured in a temperature controlled measuring room, x- and y-axis, top, middle & bottom of the barrel and it was all well within spec.
Ah ok that's interesting. My friend is quite into two strokes and told me there is only one place in JHB that does nicasil plating.
properly yes just the one. 👍😎
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 02, 2019, 08:23:37 am
Just a question...did you rebore or hone the barrel? I stand under correction but I believe the BMW 650 barrel is nikasil plated.

Correct - Nikasil coated - and we didn't bore it because it still had the original cross-hatching marks on it, and we also had it measured in a temperature controlled measuring room, x- and y-axis, top, middle & bottom of the barrel and it was all well within spec.
Ah ok that's interesting. My friend is quite into two strokes and told me there is only one place in JHB that does nicasil plating.
properly yes just the one. 👍😎

Whom, pray tell?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 02, 2019, 09:27:22 am
Did about 110km yesterday morning with Halfdaft and a new WD, then home to inspect - there is a small leak on the drive-shaft (suspect it worn), but nothing to stop a good ride! We rode quite hard (for me anyway), some great tar to open up the top-end, some awesome twin- and single-track, the X handles the tight stuff brilliantly, I cannot get over what I've been missing!!

Home lfor a was...

Cheers!!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 02, 2019, 09:28:13 am
NOW the Mods & Farkles begin - the story has not ended.....

 :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 07, 2019, 09:55:43 am
Except for the leaky final drive seal, she's going like stink - i am loving this bike!!

Final Drive is leaking a little, not too major, but as I already replaced the seal, it COULD be that a new drive-shaft is required, which would be a little tragic as then every single gasket needs to be replaced again.....

Ah well!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on May 07, 2019, 05:22:58 pm
When you start saying Ah Well, it is definitely a SHE!☺

It is interesting to note the unintended consequences of wear and tear - it is not always taken into consideration when taking on an older or high km vehicle.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Welsh on May 07, 2019, 06:39:34 pm
Except for the leaky final drive seal, she's going like stink - i am loving this bike!!

Final Drive is leaking a little, not too major, but as I already replaced the seal, it COULD be that a new drive-shaft is required, which would be a little tragic as then every single gasket needs to be replaced again.....

Ah well!!
is the bearing removable from outside, bearing and seal would be my first option 👍
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 09, 2019, 07:26:10 am
Except for the leaky final drive seal, she's going like stink - i am loving this bike!!

Final Drive is leaking a little, not too major, but as I already replaced the seal, it COULD be that a new drive-shaft is required, which would be a little tragic as then every single gasket needs to be replaced again.....

Ah well!!
is the bearing removable from outside, bearing and seal would be my first option 👍

Bearing no, its internal, as well as being a brand new sealed unit, but seal, yes, that's an external press-in.

BUT there is no excuse for stoopid. Cant be excused. It's just doff.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Piet on May 09, 2019, 09:10:47 am

Bearing no, its internal, as well as being a brand new sealed unit, but seal, yes, that's an external press-in.

BUT there is no excuse for stoopid. Cant be excused. It's just doff.
Is the final drive seal another term for counter-sprocket shaft seal? If that seal is ANYTHING like the KLR's, then I would replace that once more before going all-in for another major operation.

I replaced mine a while back and it is UNBELIEVABLY prone to damage. I damaged the first (no visual damage, but slow seepage) and then replaced again to achieve success. I sleeved the shaft by folding oil-covered paper around it so that the seal can slide over without damage.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 09, 2019, 09:35:54 am

Is the final drive seal another term for counter-sprocket shaft seal? If that seal is ANYTHING like the KLR's, then I would replace that once more before going all-in for another major operation.


Yup - thats the one!!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 09, 2019, 09:46:13 am
So, to explain the Doff-ness of me, lets investigate....

I had the oil leak from the final drive/countershaft area, so yesterday I stripped off the cover and removed the drive sprocket, the back looks like this....

(https://i.postimg.cc/Xvm6fWSG/PIC-12-2.jpg)

So the indication is there that oil is spraying up from the shaft, so we know where the oil is coming from...

Upon investigation we see this....

(https://i.postimg.cc/kgjm58Ty/PIC-12-3.jpg)

The mechanically able will recognise that the silver ring is the seal on the internal bearing and between us and that, there should be a seal.....

So you can deduct why the Doff is mentioned....

Searched my parts bins and discovered....

(https://i.postimg.cc/dVQFvnj1/PIC-12-4.jpg)

And then had to face my own stupidity, not once, not twice, but thrice!
I obviously fitted the bearings in the engine case, with the view that I would install the seal when the engine was assembled and I could turn it over, 2nd in-attentive moment would have been when I installed the drive sprocket, surely I should have seen the lack of seal then? And thirdly, when I was cleaning up and saw a sealed packet of seals (I ordered 2), I should have asked the question, but no.....

Anyway, after berating myself with beer, I fitted the seal and re-assembled...

(https://i.postimg.cc/6QyN43Sx/PIC-12-5.jpg)

Embarrassing is what it is!

 :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Black_Hawk on May 09, 2019, 09:55:23 am
So leer 'n mens mos maar  :pot:

Gelukkig was dit 'n eenvoudige oplossing gewees.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: LoopSoosStroop on May 09, 2019, 10:00:45 am
Gelukkig was dit 'n eenvoudige oplossing gewees.

Ai as dit maar net altyd so eenvoudig was....

Good work mr Turtle!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 09, 2019, 10:43:08 am
Gelukkig was dit 'n eenvoudige oplossing gewees.

Ai as dit maar net altyd so eenvoudig was....

Good work mr Turtle!

Makes one feel a little silly though!

On the up-side, I removed the seal on the inside of the bearing to allow oil ingress, but left the outside covered - would have been much worse if not for that! Bear in mind we have ridden a few 100km's already on this, so very little usage - Only noticed it when we finished the ride actually....

This weekend we do fork oil I think - just going to replace it for good measure - no issues, but who knows when last it was done.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Welsh on May 09, 2019, 10:48:23 am
Gelukkig was dit 'n eenvoudige oplossing gewees.

Ai as dit maar net altyd so eenvoudig was....

Good work mr Turtle!

Makes one feel a little silly though!

On the up-side, I removed the seal on the inside of the bearing to allow oil ingress, but left the outside covered - would have been much worse if not for that! Bear in mind we have ridden a few 100km's already on this, so very little usage - Only noticed it when we finished the ride actually....

This weekend we do fork oil I think - just going to replace it for good measure - no issues, but who knows when last it was done.....

 :lol8: :lol8: Turtle just for info, on my R1150GS gearbox all of the main gearbox bearings are double sealed, they do not run in the gearbox oil.  :thumleft: 8)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 09, 2019, 11:26:01 am
:lol8: :lol8: Turtle just for info, on my R1150GS gearbox all of the main gearbox bearings are double sealed, they do not run in the gearbox oil.  :thumleft: 8)

Ian - we had this discussion, Halfdaft and I, about whether to leave the seals in or not, the bearings are pre-greased as we know.

In the end I opened them up on the theory that they would benefit from being exposed to the circulating oil - downside is that if there was a component failure in the engine, they would get the shrapnel as well - but as the OEM bearings are all open, I decided to go with it, except where the one side was a shaft exiting the box....

Maybe flawed logic, but it's my own!  :biggrin:

But i am loving the bike.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Welsh on May 09, 2019, 11:41:33 am
:lol8: :lol8: Turtle just for info, on my R1150GS gearbox all of the main gearbox bearings are double sealed, they do not run in the gearbox oil.  :thumleft: 8)

Ian - we had this discussion, Halfdaft and I, about whether to leave the seals in or not, the bearings are pre-greased as we know.

In the end I opened them up on the theory that they would benefit from being exposed to the circulating oil - downside is that if there was a component failure in the engine, they would get the shrapnel as well - but as the OEM bearings are all open, I decided to go with it, except where the one side was a shaft exiting the box....

Maybe flawed logic, but it's my own!  :biggrin:

But i am loving the bike.....

No issue, was just mentioning it.  :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on May 09, 2019, 12:28:24 pm
So no problematic wear on the output shaft then. That's a bonus!!!
On the front shock. To stiffen it up a bit, Martin from MP Valve in Cape Town uses slightly thicker oil, or just a few mm more. To make it 10% stiffer he would shorten the spring by one turn, and manufacture a plastic spacer to take up the slack.
my 2c...
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Piet on May 09, 2019, 12:35:15 pm
So, to explain the Doff-ness of me, lets investigate....

I had the oil leak from the final drive/countershaft area, so yesterday I stripped off the cover and removed the drive sprocket, the back looks like this....

So the indication is there that oil is spraying up from the shaft, so we know where the oil is coming from...

Upon investigation we see this....


The mechanically able will recognise that the silver ring is the seal on the internal bearing and between us and that, there should be a seal.....

So you can deduct why the Doff is mentioned....

Searched my parts bins and discovered....

And then had to face my own stupidity, not once, not twice, but thrice!
I obviously fitted the bearings in the engine case, with the view that I would install the seal when the engine was assembled and I could turn it over, 2nd in-attentive moment would have been when I installed the drive sprocket, surely I should have seen the lack of seal then? And thirdly, when I was cleaning up and saw a sealed packet of seals (I ordered 2), I should have asked the question, but no.....

Anyway, after berating myself with beer, I fitted the seal and re-assembled...

Embarrassing is what it is!

 :biggrin:
:imaposer: Yes, I guess one should confirm that it is IN PLACE before considering REPLACING it.

I'm so glad that it was a simple fix and that you caught it in time!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 09, 2019, 12:38:14 pm
So no problematic wear on the output shaft then. That's a bonus!!!
On the front shock. To stiffen it up a bit, Martin from MP Valve in Cape Town uses slightly thicker oil, or just a few mm more. To make it 10% stiffer he would shorten the spring by one turn, and manufacture a plastic spacer to take up the slack.
my 2c...

Yup - I tried to get hold of MP regarding my rear shock (its too light for my Unique Physique) but after more than a few months trying I gave up. BlingKing is getting me a new spring.
The specified oil is a 7.5-Weight, and I have 10-weight at home, so the plan is to mix up a batch, maybe make it more 8-weight than 7.5-weight..... and add 3mm more....  :biggrin:
Realistically, the front is not actually the problem, but the back is bottoming out too easily. its a 122Nm spring, so going up to a 140Nm but same length (trying to get a longer one as well)
We shall see!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Welsh on May 09, 2019, 12:39:44 pm
Ok so one cam bucket shim, one oil seal, any other extra parts left over?  ::)  :imaposer:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 09, 2019, 12:40:03 pm
:imaposer: Yes, I guess one should confirm that it is IN PLACE before considering REPLACING it.
[/quote]

You see now.

My defense is that it's out of view behind the sprocket.

 :imaposer:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 09, 2019, 12:41:03 pm
Ok so one cam bucket shim, one oil seal, any other extra parts left over?  ::)  :imaposer:

I REALLY dont think there is any need to making a tally here....

Move along.....

Nothing to see....





But I will check.....  :biggrin:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Jacobsroodt on May 09, 2019, 12:50:20 pm
So no problematic wear on the output shaft then. That's a bonus!!!
On the front shock. To stiffen it up a bit, Martin from MP Valve in Cape Town uses slightly thicker oil, or just a few mm more. To make it 10% stiffer he would shorten the spring by one turn, and manufacture a plastic spacer to take up the slack.
my 2c...

Yup - I tried to get hold of MP regarding my rear shock (its too light for my Unique Physique) but after more than a few months trying I gave up. BlingKing is getting me a new spring.
The specified oil is a 7.5-Weight, and I have 10-weight at home, so the plan is to mix up a batch, maybe make it more 8-weight than 7.5-weight..... and add 3mm more....  :biggrin:
Realistically, the front is not actually the problem, but the back is bottoming out too easily. its a 122Nm spring, so going up to a 140Nm but same length (trying to get a longer one as well)
We shall see!
Martin did the same for the rear suspension on my Honda CRF230F. He removed a full turn? of the back suspension, fitted a plastic spacer and assembled after servicing. Now the rear suspension extends fully unladen and is a bit firmer when ridden.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 13, 2019, 09:29:11 am
OK, so I got in a few hours on Saturday - First of all, this arrived....

(https://i.postimg.cc/1zsLxzHh/PIC-12-6.jpg)

And were summarily installed.... PRETTY!!!

(https://i.postimg.cc/zGn9PhTF/PIC-12-7.jpg)

Next up was replacing the fork oil - I bought Motul 10W & 5W and mixed them 50/50 for a W7.5....

(https://i.postimg.cc/3Rb6DFHY/PIC-12-8.jpg)

One at a time, keeping order....

(https://i.postimg.cc/fLbpLgp8/PIC-12-9.jpg)

The forks have not been installed as yet as I want to remove the top triple clamp with a view to getting a plate lazer-cut to install a steering damper, and to sort out the hoer-nes thats the wiring behind the gauges.....

Also, @Halfdaft is busy making up a bracket to hold the 5-litre fuel tank I bought recently....

(https://i.postimg.cc/q7wWpdbt/PIC-13-0.jpg)

More farkles to follow.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: Supervan on May 17, 2019, 08:58:05 am
OK, so I got in a few hours on Saturday - First of all, this arrived....



And were summarily installed.... PRETTY!!!



Next up was replacing the fork oil - I bought Motul 10W & 5W and mixed them 50/50 for a W7.5....


One at a time, keeping order....



The forks have not been installed as yet as I want to remove the top triple clamp with a view to getting a plate lazer-cut to install a steering damper, and to sort out the hoer-nes thats the wiring behind the gauges.....

Also, @Halfdaft is busy making up a bracket to hold the 5-litre fuel tank I bought recently....


More farkles to follow.....

I would really like a write-up on the fork oil replacement. My XCountry is on 45000km and I think it is time, but I am shit scared that something is going to go booooing through my arm and into the roof. How did they always say on Top Gear: "Ambitious but shit." Kinda sums up the situation with me regarding the shock oil replacement.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 17, 2019, 10:15:15 am
OK, so I got in a few hours on Saturday - First of all, this arrived....



And were summarily installed.... PRETTY!!!



Next up was replacing the fork oil - I bought Motul 10W & 5W and mixed them 50/50 for a W7.5....


One at a time, keeping order....



The forks have not been installed as yet as I want to remove the top triple clamp with a view to getting a plate lazer-cut to install a steering damper, and to sort out the hoer-nes thats the wiring behind the gauges.....

Also, @Halfdaft is busy making up a bracket to hold the 5-litre fuel tank I bought recently....


More farkles to follow.....

I would really like a write-up on the fork oil replacement. My XCountry is on 45000km and I think it is time, but I am shit scared that something is going to go booooing through my arm and into the roof. How did they always say on Top Gear: "Ambitious but shit." Kinda sums up the situation with me regarding the shock oil replacement.

Very easy to do - Nothing is under pressure, so nothing flies around.

PM me your email and I will see if i can download the section of the RepROM file and mail it to you. If you can swing a spanner, you can do this - take your time, follow the steps and it can be done.

Hoping my new rear spring arrives today, we are riding on Sunday!
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 21, 2019, 11:44:09 am
So a few bits are happening, along with the fuel cell range extender, chief of which is the addition of a Scotts Dampener, but unfortunately there is no "plug 7 play" option for the X-challenge, so innovation was required, along with design, prototyping, and modification - @Halfdaft would get a load more done if he didn't have my problems in his life....  :thumleft: Thank you Richard!

So first up was the removal of the top triple-clamp, and then the old-fashioned pencil & paper version of CAD to get the initial drawings dimensionally accurate,

(https://i.postimg.cc/dVZ8CVZX/PIC-13-1.jpg)

To achieve something like this...

(https://i.postimg.cc/mZVNfqGd/PIC-13-2.jpg)

Then off to HalfDaft to do this

(https://i.postimg.cc/vHB7QzYG/PIC-13-3.jpg)

(https://i.postimg.cc/j5tNB630/PIC-13-4.jpg)

and this is the resultant prototype in-situ - we have procured aluminium block to machine the end result once the prototype is confirmed accurate and correct....

(https://i.postimg.cc/fbxmHqKf/PIC-13-5.jpg)

Its 12mm thick 3D printed plastic - this will give us a good idea of what mods need to be done before it goes to machining.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 21, 2019, 11:49:37 am
Also, on Friday morning, @BlingKing contacted me to advise the new Wilbers spring had arrived - better suited to my Unique Physique....

Old Spring...
(https://i.postimg.cc/dtx2Dy3r/PIC-13-6.jpg)

New Bling!!
(https://i.postimg.cc/yxfFmJPq/PIC-13-7.jpg)

Installation was pretty straight-forward, off with the rear wheel, undo the 2 compression ring-nuts to take the pressure off the spring, remove the bottom bolt (who designed it so that there is a cap-screw some 40mm down inside a blind hole so that you battle to get it out...?), remove the C-washer from the bottom of the shock and slide the spring out from underneath - reverse to install!

(https://i.postimg.cc/PqG1Qnmq/PIC-13-8.jpg)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: LoopSoosStroop on May 21, 2019, 12:10:53 pm
Might be a tad easier to have that plate waterjet or laser cut than to machine?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 21, 2019, 12:12:56 pm
Might be a tad easier to have that plate waterjet or laser cut than to machine?

Probably - but HalfDaft has a small CNC mill at home..... :thumleft:
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 29, 2019, 02:36:39 pm
So the next step was to remove/install/remove/install the top triple-clamp and get the dampener mounted, dully completed as so

(https://i.postimg.cc/s2q5TVfG/PIC-13-9.jpg)

(https://i.postimg.cc/cCNwNXns/PIC-14-0.jpg)

And then onto the the pin that supplies the pressure for the dampener to work - there is no off-the-shelf solution for this, and I was not in favour of welding a bracket to the frame, so I saw another thread where the protagonist built a bracket over the top of the centre support frame,so I went with that option....

First step, as always, is to make a template, and test-fit it....

(https://i.postimg.cc/3J1pPjJT/PIC-14-1.jpg)

(https://i.postimg.cc/9XGyB56z/PIC-14-2.jpg)

Next, was to cut some 3mm steel plate into the correct shape, trim some folding channels, and cold-bend it in the vice - it came out a bit skew, but nothing that some abuse with a 4lb hammer couldn't rectify....
Grabbed an extended 8mm cap-screw, cut it off, ground the correct (eyeballed) angle onto it and welded it in place, having removed the battery and ECU, and trimmed the end flat....

(https://i.postimg.cc/T3PmGypW/PIC-14-3.jpg)

A little touch-up paint, and leave it to dry....

(https://i.postimg.cc/3RGm6PWS/PIC-14-4.jpg)

Next day - installed...

(https://i.postimg.cc/brHbYkx1/PIC-14-5.jpg)

(https://i.postimg.cc/FsN3WCvp/PIC-14-6.jpg)

Covers fitted - looks great!!

(https://i.postimg.cc/ht3mGSdZ/PIC-14-7.jpg)

Then on Sunday, off for a test ride, with some fella's from the South, had a great ride nothing broke..... No pics as I left my water reservoir at home, with everything in it....

And the @Halfdaft sent me pics of the new top-bracket he has finished machining - this is purrdy!!!

(https://i.postimg.cc/YSGWGJNr/PIC-14-8.jpg)

(https://i.postimg.cc/hGk79pM9/PIC-14-8.jpg)

He also had a couple of flat plates laser-cut, to support the tail section, which is cracked, and has a load of flex, so we designed these shiny bits behind the indicators....

(https://i.postimg.cc/1tDVMwYb/PIC-14-9.jpg)

(https://i.postimg.cc/90VRk060/PIC-15-0.jpg)

Next Time......
The fuel cell brackets I think?
And maybe some ride pics.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: noble steed on May 30, 2019, 12:00:49 pm
My tail section was just strengthened with some flat steel plate, a hacksaw and black spray paint. Not as pretty, but does the job!

I've never had any problems with the front end twitching, so never felt the need for a damper. Does it make a big difference? (In the limited amount of riding you've done on the X)
Maybe I just don't ride fast enough...
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on May 30, 2019, 12:12:53 pm
My tail section was just strengthened with some flat steel plate, a hacksaw and black spray paint. Not as pretty, but does the job!

I've never had any problems with the front end twitching, so never felt the need for a damper. Does it make a big difference? (In the limited amount of riding you've done on the X)
Maybe I just don't ride fast enough...

Saved my arse twice on Sunday - once on a fairly steep off-camber downhill, long right, was probably going faster than normal, but probably no more than about 50kmh, so not that quick or anything, we were a IT490, XR650L with a load of suspension bits, CRF450, KLR650 - I was behind the IT490, clipped a rock on the left which threw the bike right, when the front bounced again, it held the line, rather than throwing me off...
Second incident was on a rocky section, about tenni-ball size, about 250m through the bush, certainly helped me there as it stopped the steering bouncing to the side... Also on the fast tracks with lots of marbles, it just helps tracking
Necessary? Probably not....
Nice to have? Hell yeah!!
And I had it at home anyway, it is interchangeable with my GSA - 2 cap screws, 20-seconds.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on June 19, 2019, 03:36:15 pm
Next was additional Fuel - I looked around and had some luck with a Long range tank, but unfortunately the funds are low until I can get the R1200GSA sold, so we must make a plane!!

First, @Halfdaft made me the hoop, with the plate welded accross the middle, with a M10 nut welded on the back. I positioned the hoop using scrap wood i had in the wood pile, held together creatively with masking tape....

(https://i.postimg.cc/GhvTswdG/PIC-15-1.jpg)

Checked for clearance and welded up some brackets, and bits & bobs... and...

(https://i.postimg.cc/bY72JNcq/PIC-15-2.jpg)

Works alright I think!

(https://i.postimg.cc/2jbZrLtH/PIC-15-3.jpg)

(https://i.postimg.cc/MpDcd7cG/PIC-15-4.jpg)

And finished product

(https://i.postimg.cc/CxYBGPxt/PIC-15-5.jpg)

Went for a 333.5km blast down to Villiers & back on some lekker dirt roads on Monday...

(https://i.postimg.cc/1XFTQ0bx/PIC-15-6.jpg)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: lone riderer on June 22, 2019, 07:39:57 am
My tail section was just strengthened with some flat steel plate, a hacksaw and black spray paint. Not as pretty, but does the job!

I've never had any problems with the front end twitching, so never felt the need for a damper. Does it make a big difference? (In the limited amount of riding you've done on the X)
Maybe I just don't ride fast enough...

Never needed one either, although my front rim may tell a different story..
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: lone riderer on June 22, 2019, 07:42:17 am
Bike is looking good! How is it running?

I need to order a new fuel filter from Ebay. Did you replace yours?
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on July 16, 2019, 01:59:18 pm
Bike is looking good! How is it running?

I need to order a new fuel filter from Ebay. Did you replace yours?

Sorry - only saw this nearly a month later - whats with that??
No - the filter looked brand new - however I am going to have to do some work around the fuel pump wiring, its a complete abortion - at some point the bike must have had the issues regarding the burnt wires, so they wired the pump direct;y, going through holes drilled in the black pump cap, and sealed with QBond - then bullet connectors on the outside - insulated - works, but not pretty...... I want to scrap the whole system and re-do the plug that goes through the cap.
Anyway, another days issues.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: lone riderer on July 16, 2019, 09:47:25 pm
I wonder if the previous owner had replaced that fuel filter then because at that mileage it should have already had issues given our conditions. Anyway, get the filter from fuelperformance.co.za for R350 and the pump for R1500 if you need.

I wanted to ask you, your usb charger, piped straight onto the battery hence the switch? I want to have mine run on ignition only but I know jack about electrics.
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on July 17, 2019, 07:39:35 am
I wonder if the previous owner had replaced that fuel filter then because at that mileage it should have already had issues given our conditions. Anyway, get the filter from fuelperformance.co.za for R350 and the pump for R1500 if you need.

I wanted to ask you, your usb charger, piped straight onto the battery hence the switch? I want to have mine run on ignition only but I know jack about electrics.

Filter/pump was probably done - I don't know the complete history, so it's very possible it was done....

The USB - it is wired directly to the battery, with a fuse (10A I think) at the battery, the unit has a built-in LED back-light, hence the switch. I had it laying at home, but if I had bought one, I would have opted for the non-illuminated unit and skipped the switch. the positioning and the plate is for ease-of-use, I haven't decided where the final position should be. Also, as my ignition switch is an after-market unit from Startline, there are additional wires that I still need to test to see what are live when the ignition key is in the 3 different "on" positions - I was in a rush when I was doing this, then I got lazy.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on July 17, 2019, 08:20:00 am
Also Added a new GPS this weekend too...

(https://i.postimg.cc/SRsypL05/PIC-15-7.jpg)

(https://i.postimg.cc/1tM9TCdw/PIC-15-8.jpg)
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: noble steed on July 17, 2019, 11:20:41 am
I wanted to ask you, your usb charger, piped straight onto the battery hence the switch? I want to have mine run on ignition only but I know jack about electrics.

I have one of these - works well, has a switch built in to adapter, GPS hasn't experienced power issues while plugged into it (yet)

https://www.ebay.com/itm/5V1-5A-Waterproof-USB-Charger-Socket-Adapter-Power-Outlet-for-12V-24V-Kq/283550869692?hash=item4204f2e8bc:m:mhPTto3dqmYpp3mfkG5LSSA

Have a 8 way fuse box (similar to this https://www.ebay.com/itm/8-Way-Standard-LED-Circuit-Blade-Fuse-Box-Kit-6-Volts-30-Amp-Way-Output-Marine/173628403606?hash=item286d0f2f96:g:KsIAAOSw5dlaEAJ3) wired to battery sitting under rally fairing, everything else, including HID lights,  all runs off that
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: ClimbingTurtle on July 17, 2019, 11:43:42 am
I wanted to ask you, your usb charger, piped straight onto the battery hence the switch? I want to have mine run on ignition only but I know jack about electrics.

I have one of these - works well, has a switch built in to adapter, GPS hasn't experienced power issues while plugged into it (yet)

https://www.ebay.com/itm/5V1-5A-Waterproof-USB-Charger-Socket-Adapter-Power-Outlet-for-12V-24V-Kq/283550869692?hash=item4204f2e8bc:m:mhPTto3dqmYpp3mfkG5LSSA

Have a 8 way fuse box (similar to this https://www.ebay.com/itm/8-Way-Standard-LED-Circuit-Blade-Fuse-Box-Kit-6-Volts-30-Amp-Way-Output-Marine/173628403606?hash=item286d0f2f96:g:KsIAAOSw5dlaEAJ3) wired to battery sitting under rally fairing, everything else, including HID lights,  all runs off that

Nice goodies - At some point I may go the Nav Tower route, then I will certainly look at that fuse setup....

That USB switch is what I need - I want to move the switch off of the handlebars and down into the dash area somehow.....
Title: Re: The Story Of The Resurrection of Blitsie….
Post by: lone riderer on July 20, 2019, 08:36:34 am
I've got the weatherproof usb with led rim light. No switch and wired direct. Ran my battery flat twice. Haven't found a proper weatherproof switch yet. I like that unit NobleSteed.

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