BMW 1200GS Rebuild Part 4

Boxes are arriving from Motorworks, so exciting but expensive. New clutch parts and complete service items, nuts and bolts and oils and seals, gaskets and spark plugs, air filters and everything that you can ever dream of! This is the final fit out before rebuilding the bike starts. The clutch has to be refitted with a new friction plate and seals changed with drifts being turned down to install each one. Getting closer.....
Normski website: normski-bmw.co.uk

[@mouradwergly3083]

Norman, is always a pleasure seeing you working with all the passion and the learnings that you share with us. Thanks for the videos.

[@aaronli4171]

So great waking up first thing to watch you at work! 👍🏻👍🏻👍🏻 can't wait to see the completed bike, you will enjoy it so much more!

[@djay9220]

Norm, I must say how much I love watching you work. I can picture the completed bike and the big smile on your face when you fire it up for the first time.

[@normski3091]

Hi Douglas, thank for your encouraging words. I keep looking at all the cables and telling myself that I know nothing about a bikes electrics 🤦🏼‍♂️. Got the engine in Monday and the gearbox this afternoon, I know I am going very slowly, but I am reading Haynes manual at every nut and bolt. If it fires up I think it will be a total surprise 🤪

[@francisguchie1973]

Very detailed videos.. Nice and awesome to watch

[@TheDervMan]

fascinating watch. Thanks for sharing.

[@tojj29]

Not sure if you've enjoyed doing the work making these Norm, but I've really enjoyed watching them so far. Can't wait till the day you fire it up. All the best with it

[@tonymarkey6525]

Normski, this is brilliant. For all of us with one of these bikes it is both entertaining and informative. Your attention to detail is great to see. I’m very grateful you are doing this. One thing I might humbly suggest. Read up on the ABS unit I have a feeling it can be removed but you retain the wiring. It’s a big lump of useless metal got rid of if you can!😁😁

[@normski3091]

Hi Tony, yes I thought the same so contacted Graham’s Motorcycles in Bradford who are probably the best in the business at bypassing the ABS units and keeping the correct dashboard lights so there is not confusion and the bike gets through the MOT. They are an amazing BMW garage. This was Stephens reply: As you mentioned, it was left on intentionally, If you were to remove the servo unit from the bike (even though its not up to much) the red triangle warning would come on and never go off. I would suggest you put it back on as it was. The bike currently ’thinks’ the ABS/Servo is working which is how we are able to keep the warning system working. Obviously a missing servo would indicate a major fault as far as the bike is concerned. Cheers Stephen

[@MrJohnmccrory]

Great vids ! Very useful and informative, I have a set of the teng tools torque wrenches and always wondered what the angles meant on the head, now I know 👍

[@normski3091]

Hi John, yes it is the first time I realised as well 😆

[@bahadurceferov.]

Thanks 👍

[@Tattytyres]

Fantastic video, i also used motorworks for my parts i changed big end bearings, i had just bought bike and did an oil change and found brass/ali particles in oil, my old shells were not too bad just mildly warn through white metal, im still not sure what has worn internally but bike runs fine and iv covered 900 miles,

[@normski3091]

Wow Matthew that is a big job, well done 👍

[@dueruote37]

Complimenti proprio un bel lavoro e grazie x aver condiviso, presto vorrei rifare la frizione al mio gs , potrebbe dare le misure del centratore del disco ? Grazie ...

[@VIDEOJMENO]

How about blowing out a lot of sawdust before removing the simering?

[@tanguyadriaenssen9755]

Generally, when replacing the clutch disk, you should also replace the pressure plate and the housing…

[@Kradmelder24]

26:46 lass den Schwamm bitte draußen. Der saugt sich nur voll mit Wasser und sorgt dafür, dass der Räderkastendeckel zu oxydieren anfängt. Der Schwamm war bis 2007 drin, danach hat BMW das Teil weggelassen. Tolle Videoreihe, danke sehr!

[@normski3091]

Absolutely right. In the end I decided to take it out, but I never knew the reason, thank you for that information...brilliant 😀

[@contakt23]

great precision work , its handy to have a lathe eh? thank you , just about to replace my clutch, cheers

[@normski3091]

Hi Eric, It is the replacing of the clutch that is one of the most fearsome jobs on the Boxer engines because of where it is. I suppose that is why it is now in the front on latest bikes! BUT if you follow a manual, step by step, that is all I did as I had never done it before. Are you in the UK? If so I will send you the tools I made if it helps you at all?

[@contakt23]

@@normski3091 hi Norm , you are very kind to offer the tools , I am in ireland and would be happy to trade you something I make for your well made tools , here's my email [e-mail] , thanks 👍

[@keithsbitsandpieces]

Just watching you put the clutch plate back on and your saying that you can put it back where ever , while at the top of the picture you can clearly see the hole where the TDC hole in the plate is

[@user-ho4fe7jz1n]

Hello..I like the video..I have a request.Can you tell me the dimensions of the clutch centering tool?I want to make it myself

[@amcart53]

The foam insert inside the front cover traps dirt and water and causes the engine casing to corrode, best to bin it IMHO.

[@normski3091]

I have just heard that this week Andy, very useful to know. Amazing how much you learn from the KZbin community, thank you very much. The bike is with a new owner now.....

[@tanguyadriaenssen9755]

Agree, I have dumped them on all my 1200 boxer engines… they always lead to corrosion and quite frankly I can’t hear the difference (they are supposed to be noise attenuators)

[@smoll.miniatures]

@@tanguyadriaenssen9755yup they are open cell foam. Madness.

[@JamesGodboldProfile]

In regards to the belt, there are two versions one is elasticated. The model you have didn't have the ELAST part of the model number which may explain your challenges. Also that foam insert behind the plastic cover caused excessive corrosion and its recommended to be removed. (it was originally installed to deaden sound)

[@normski3091]

Well James that is interesting, I never knew or ever found an alternator belt that was elasticated. Motoworks never showed one for sale here in the UK. What a difference that would make. That will be why I have had a couple of comments saying ‘waste of time just wind it on’ which is totally impossible......unless you had one that would stretch👌🏼 A revelation and the information about the foam😍

[@JamesGodboldProfile]

@@normski3091 brilliant videos, really inspired me to get my hands dirty and not be afraid to just crack on and work through the problems.

[@normski3091]

@@JamesGodboldProfile good on you James, go for it 🤗

[@coarsegoldkid]

Hi there Normski, can you give me your knowledge about what's behind that square piece under the lower alternator belt pulley. I found that my RT was leaking from there. I replaced the O-ring behind it but it's still leaking. I'm thinking there's a seal in there but I could not see one. Thanks

[@normski3091]

Hi Joe, I am really at a loss there Joe. I sold the bike not long after I rebuilt it and gave the new owner the Haynes Manual for that model so cannot even look it up for you. Sorry I am of no help 😪

[@kevinansell9341]

Norman, I noticed that the spec for that Counter balance Bolt stated Replace, I always thought any Bolt fastened down with an Angle reference was a stretch Bolt and needed replacing ?

[@normski3091]

Yes well spotted Kevin. I noticed that on the torque setting info I printed off the Internet but not in Haynes Manual (or was it the other way round) and also not specified by Motorworks who always say ‘these bolts must be replaced’ as they do and I did on the clutch bolts? 🤷‍♂️😰🤦🏼‍♂️

[@kevinansell9341]

@@normski3091 Odd as my BMW service manual CD says:- Neck-down screw, M8 x 70, Replace screw Tightening torque, 10 Nm Additional angle of rotation, 90° Lets hope she holds :)

[@normski3091]

@@kevinansell9341 Yes let's hope so Kevin. I have just checked my Manual and Motorworks and they do not say they need to be changed BUT I tend to believe that they should??? Too late now. Going on a long ride tomorrow on the GS with two more IAM guys....so watch this space?

[@francisguchie1973]

Kindly share the specifications for the counter balance oil seal

[@normski3091]

Hi Francis, I really would like to but when I sold the GS I gave the new owner two full files of every invoice for every single part I bought, so I have no details anymore. However Motorworks in England is who I bought the seals from. Their website is very good and you can find all the seals, for example: Input shaft rear seal | GEA56019 Fits R1200GS (09/2003 - 08/2007), R1200GS (09/2007 - 08/2009), R1200GS... Show All... Associated BMW part: 23127705085 (23 12 7 705 085) view larger image Larger Image The input shaft has two seals. This is the seal at the back of the gearbox under the clutch slave cylinder. It is a gearbox oil seal NOT a slave cylinder fluid seal. £12.79 INC VAT £10.66 EX VAT UK VAT will not be charged on non UK orders Quantity add to basket

[@fazedordechuva8810]

👏🏻👏🏻👏🏻👏🏻👏🏻👏🏻🔝🔝🔝🔝🔝

[@TheFrontLinesGamer]

Hello, are there any aftermarket clutch kit for Bmw r1200gsa 2010 DOHC? I want to replace the whole kit, but I don’t find and alternative than the bmw original parts, thanks in advanced.

[@normski3091]

Hi Jorge, Yes Motorworks in North Yorkshire do all the parts and ship anywhere in the world: www.motorworks.co.uk Hope that helps!

[@meintjiesj]

Maybe I missed it but how did you get that seal out you were replacing last in this video?

[@normski3091]

Hi Johan....let me look through the video again and see which one it was!

[@normski3091]

Hi Johan, I managed, although not always easy, to get all the seals out the same way. I drilled two small holes in the old seal opposite each other and screwed in self tapping screws. Then with bent nose pliers I very slowly pulled on each screw. Once starts to free you are away, however sometimes I would pull a screw out and have to re-drill another hole. The difficult ones often had a number of holes around the seal🤦🏼‍♂️

[@meintjiesj]

@@normski3091 thanks for the confirmation. I saw you do it on ones that were flush with the surface but that one looked very deep. Learnt a few tricks watching your rebuilt videos.

[@tanguyadriaenssen9755]

12Nm for the clutch cover plate… 8Nm is for the clutch top cover screws (plastic top)

[@allbikerepairing8878]

Sar I am Indian main bhi aapse Milana chahta hun aur kam sikhana chahta hun main bhi ek two wheeler mechanic hun

[@user-ho4fe7jz1n]

Hello..I like the video..I have a request.Can you tell me the dimensions of the clutch centering tool?I want to make it myself