Welcome, Guest. Please Login or Register

Author Topic: Ian Been's GS 1200 Rebuild Fred  (Read 12420 times)

0 Members and 1 Guest are viewing this topic.

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Ian Been's GS 1200 Rebuild Fred
« on: August 04, 2014, 05:15:11 pm »
Ok so Pleco's fred inspired me to take on my own engine rebuild. I should have taken a bit more note on the stripping of the bike because in hindsight I think I went a bit bos.

What promted the tear down.

I noticed a knock/clatter at around 3500 - 4000 rpms under load. The bike had a bit of a noise when I bought it at 80 000kms but being a novice on oilheads I thought this was normal.

When it became really too loud(in my opinion) I took it to a reputable bmw maccy (also showed me two bm's in the shop with similar issues) and he suggested I drain the oil and strain it and see what comes out. I did and found a few minute slivers of brass material also metalic bras coloured particles in the oil. Where will you find brass in the bmw motor....possibly from small end bushes??

I was told these bikes dont have small ends but I have found that they do.
« Last Edit: August 04, 2014, 05:37:17 pm by Ianbeen »
Just an old dog looking to learn a few new tricks.
 

Offline ChrisL - DUSTRIDERS

  • Forum Vendor
  • Castrated Dog
  • ******
  • Bike: BMW R1200GS
    Location: Western Cape
  • Posts: 29,419
  • Thanked: 471 times
    • dustriders.co.za
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #1 on: August 04, 2014, 05:18:52 pm »
Waiting for da pics of the engine in a 1000 pieces all over the garage floor......................................nope forgot
you do not work like that!! ;)
MOTORCYCLE ACCESSORIES RETAILER
info@dustriders.co.za
ENDURISTAN SOFTLUGGAGE IMPORTER
www.dustriders.co.za
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #2 on: August 04, 2014, 05:21:54 pm »
I'll just throw in a couple of tear down shots...You guys have probably already seen a zillion. Like I said I went a bit bos and now the braai room is "carpeted in GS spares. Luckily wifey is away visiting her sister in the Emirates for a month. Now that parking is MINE .
Just an old dog looking to learn a few new tricks.
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #3 on: August 04, 2014, 05:23:34 pm »
Waiting for da pics of the engine in a 1000 pieces all over the garage floor......................................nope forgot
you do not work like that!! ;)

LOL! Nope engine pieces all neatly together in little batches and buckets....left and right..... the rest is all over the braai room floor.>:D
Just an old dog looking to learn a few new tricks.
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #4 on: August 04, 2014, 05:26:19 pm »
Some more pics.
Just an old dog looking to learn a few new tricks.
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #5 on: August 04, 2014, 05:36:30 pm »
This is the left piston. worn out on the top skirt with some scoring. Price for ONE new piston at A&S is R3500....so ebay is my freind. I found a guy in.........wait for it............drum rolll............Lithuania! Tears down these bikes and sells off individual parts. So I bought a pair of 2007 model pistons for "A" size cylinders with 6000kms on them for R2200 post included. These have rings and gudgeon pins included.

Worth noting that my cylinders are in perfect condition. Beautiful cross hatch still highly visible.
Just an old dog looking to learn a few new tricks.
 

Offline ChrisL - DUSTRIDERS

  • Forum Vendor
  • Castrated Dog
  • ******
  • Bike: BMW R1200GS
    Location: Western Cape
  • Posts: 29,419
  • Thanked: 471 times
    • dustriders.co.za
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #6 on: August 04, 2014, 05:39:01 pm »
Ian could one drop the motor without taking the frontend off?

Engine seems so small with everything off.
MOTORCYCLE ACCESSORIES RETAILER
info@dustriders.co.za
ENDURISTAN SOFTLUGGAGE IMPORTER
www.dustriders.co.za
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #7 on: August 04, 2014, 05:45:33 pm »
The top gear on the crank was a real bitch to get off. Put it under ttension wif the puller , applied heat till slightly blue. Then gave it a few firm taps all round with a plastic hammer and she popped right off.

My little garage is really getting cluttered now. These are now in the braai/gs spares room.

What I find very interesting is the anti backlash system on the bottom gear. Its split and spring loaded so no backlash on the counterweight shaft.....Very cool. They use a similar setup on big printing presses to eliminate backlash. I love to discover stuff like this.
« Last Edit: August 04, 2014, 05:59:46 pm by Ianbeen »
Just an old dog looking to learn a few new tricks.
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #8 on: August 04, 2014, 05:50:23 pm »
Ian could one drop the motor without taking the frontend off?

Engine seems so small with everything off.

No you cant. The motor forms part of the frame so essentially you must strip everything off till you left with the motor. Pleco's fred is a better example of how to strip...I took way too much stuff loose. But then I can also do more checks on stuff like suspension bearings etc when I assemble. I also want to do a repair on the diff. Went onto a rough dirt raod with a loose hugger and it snapped the ally mounting lug off and jammed itself between the wheel and the rear shock.
Just an old dog looking to learn a few new tricks.
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #9 on: August 04, 2014, 05:53:50 pm »
Mains don't look too bad.  These would be the green ones so already placed an order for all new bearings.

The cranks looks great and I measured no ovality .

Mains 59.95mm
Big Ends 47,98mm
Just an old dog looking to learn a few new tricks.
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #10 on: August 04, 2014, 05:57:08 pm »
This a shot of the right side big end. Juuuuust started to wear into the copper.

Will post more pics shortly.
Just an old dog looking to learn a few new tricks.
 

Offline woody1

  • Forum Whore
  • ****
  • Bike: Yamaha Super Tenere
    Location: Western Cape
  • Posts: 9,975
  • Thanked: 192 times
  • XT1200ZE "Vinnige" Witte
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #11 on: August 04, 2014, 06:02:07 pm »
Wife gone away... then who's bag is that on the table ?  :imaposer:

I WOULD RATHER BE AN HONEST ASSHOLE .... THAN A FLIPPEN LIAR !   


Ducati 100cc Mountaineer, Honda 550 K3, Suzuki Gs1000E, Suzuki Gs1000G, Suzuki 1100 Katana, BMW R1100RT, BMW R1150RT,,,,,All gone. Only 2014 ST in the garage at the moment... And Honda XL 600
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #12 on: August 04, 2014, 06:28:58 pm »
Wife gone away... then who's bag is that on the table ?  :imaposer:


Eish...................You got me....Its mine..... >:D


Just kidding....My daughters.
« Last Edit: August 04, 2014, 06:30:31 pm by Ianbeen »
Just an old dog looking to learn a few new tricks.
 

Offline DirtCopper

  • Bikers have more fun than people
  • Senior Member
  • ***
  • Bike: BMW R1200GS
    Location: Western Cape
  • Posts: 1,185
  • Thanked: 1 times
  • TAKE ME TO YOUR DEALER
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #13 on: August 04, 2014, 06:39:10 pm »
 :sip:
Die SHERIFF van Groothond
 

Offline woody1

  • Forum Whore
  • ****
  • Bike: Yamaha Super Tenere
    Location: Western Cape
  • Posts: 9,975
  • Thanked: 192 times
  • XT1200ZE "Vinnige" Witte
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #14 on: August 04, 2014, 06:41:54 pm »
 :imaposer: lekker werk  :thumleft:

I WOULD RATHER BE AN HONEST ASSHOLE .... THAN A FLIPPEN LIAR !   


Ducati 100cc Mountaineer, Honda 550 K3, Suzuki Gs1000E, Suzuki Gs1000G, Suzuki 1100 Katana, BMW R1100RT, BMW R1150RT,,,,,All gone. Only 2014 ST in the garage at the moment... And Honda XL 600
 

Offline SmuGS

  • A very quiet
  • Senior Member
  • ***
  • Bike: BMW R1150GS
    Location: Eastern Cape
  • Posts: 3,231
  • Thanked: 51 times
  • Only 98 946 km.
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #15 on: August 04, 2014, 06:49:56 pm »
 :sip: I'm a printing press technician, interesting to see they use that technology in a bike engine..
Nee wat vlekkelose ek kuier op my lekkerste tussen die rokers,dronkgatte,vloekers,hoere en ander sondaars  :imaposer:
R1150gs,  KLE 500, XT660R.
 

Offline katana

  • One day when I grow up, I want to be a
  • Senior Member
  • ***
  • Bike: Honda XR650L
    Location: Western Cape
  • Posts: 4,920
  • Thanked: 121 times
  • Sheer Smiling Pleasure
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #16 on: August 04, 2014, 08:22:42 pm »
Sub.  Good luck   :thumleft:
"The only man that has to remember anything, is the man who tells a lie" Mark Twain
 

Offline Goose

  • NAPIER Country life is great!
  • Shop Mods
  • Forum Whore
  • *
  • Bike: BMW R1200GS Adventure
    Location: Western Cape
  • Posts: 8,150
  • Thanked: 10 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #17 on: August 04, 2014, 08:44:28 pm »
sub......... good one this!
"Life is a Waste of Time..... Time is a Waste of Life........ Get Wasted all the Time and have the Time of your Life"  ()
 

Offline Ianbeen

  • Senior Member
  • ***
  • Bike: Honda XL1000V Varadero
    Location: Western Cape
  • Posts: 661
  • Thanked: 1 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #18 on: August 04, 2014, 09:39:54 pm »
:sip: I'm a printing press technician, interesting to see they use that technology in a bike engine..

For sure Smuggy. Im a maintenance fitter at Nampak closures and we do it all. Metal sheet printing on raw plate before it goes to the metal presses. Very much the same as paper. I worked for a while in the machine shop of a company that repairs printing machines too...Pressma 2001. Didnt do actual work on printers but repaired the parts the maintenance guys brought in.....and zillions of bloody rollers.
Just an old dog looking to learn a few new tricks.
 

Offline ratrap

  • Senior Member
  • ***
  • Bike: Honda XRV 750 Africa Twin
    Location: Western Cape
  • Posts: 2,452
  • Thanked: 17 times
Re: Ian Been's GS 1200 Rebuild Fred
« Reply #19 on: August 04, 2014, 09:44:28 pm »
How come 2StrokeDan hasnt been here yet??  :biggrin:
No matter how much you push the envelope, it'll still be stationery.