ADVrider

Go Back   ADVrider > Bikes > GSpot > Parallel Universe
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 10-14-2008, 07:56 PM   #1
Keystone OP
Gnarly Adventurer
 
Joined: Jun 2008
Location: Lake Villa, IL
Oddometer: 201
How to break an F800GS radiator

This weekend I participated in the Pine Barrens 300 ride in Southern New Jersey. The bike performed well, but I'll post some notes on that in a separate thread. First let me tell you about my broken radiator.

Two weeks before the PB300 I put the knobbies on the bike. A TKC80 in the rear and a 908rr in the front. I took the bike over to a local off road riding area where I put the knobbies through their paces with great satisfaction.

As I was nearing the end of my session the rear washed out while running through one easy mud muddle and I went "thump" down on the left side of the bike into soft mud.

It was a very minor fall (apart from trapping my leg which was protected by my knee braces and MX boots) and I fully expected the bike to shrug it off. When I got the bike to solid ground I found that it was steaming more than usual. Thinking (correctly) I was leaking coolant I headed for the road posthaste (couple hundred yards away) to inspect further.

I found that the lower radiator hose was almost off of the water pump, and that I didn't have the pliers necessary to operate the spring clips and reset it, so I snugged the hose on as best I could and rode a couple miles back to the house, by which time the hose had pushed itself all the way off and I was just beginning to deal with uncomfortably rising coolant temperatures.

I pulled into the garage and took all the plastic off the bike:


The offending hose:


Why did the radiator hose pop off? Well, CONTRARY to other reports I've read the radiator is actually pretty securely mounted in FOUR points apart from the tab at the bottom that I don't really count. It's held by three plastic pegs that fit in rubber grommits at the end of plastic arms mounted to the frame. These control forward, backward, up and down movement but allow side to side movement.

Here's an example of one of the three arms -- the peg was pushed out by the fall and is behind the arm, but it fits snugly in that loop:


There there is a plastic loop with a grommit inside it that allows the radiator to be screwed to the frame and control horizontal movement (and to a lesser degree those other axis).

The fall cracked mine, pushing the radiator to the left:


The big damage, though, was the upper left mount. Instead of being pushed out of the grommit as designed it SNAPPED. Was it the arm, which is replaceable and held on by two screws? Nope, it was the peg which is riveted to the radiator:



FYI, a radiator is about $400. By the way, it seems BMW is aware of a problem with this mount. They have a repair kit in the parts fiche SPECIFICALLY for this mount. Based on that I'm going to see if it will be warranteed, but regardless, I wanted to fix it now, so here's what I did:

I drilled two holes through the remaining mount:


Then drilled one hole through the broken piece:


I epoxied the two together, then zip tied the pieces for security:


Finally, to enhance the ability of the peg to slide laterally instead of snap I applied grease to the peg. For those of you who have not yet had your mount snap, I recommend you do this as a preventative measure:


The finished product:


The lower right ring I simply screwed back in place. I'm not sure what I can do to prevent that from breaking further at this point (other than mounting crash bars, which are backordered).

I also bought some regular screw-type hose clamps, spray painted them flat black, and replaced the spring clips so I'd have road servicable hoses. I think they came out rather well, and now all I need is a screwdriver, or a quarter in a pinch:
__________________
Cheers,
Tom
'09 F800GS (Yellow)
'05 F650GS (Sold)
'04 K1200RS (Sold)
'03 F650GS (Crashed)
(formerly hyperiate)

http://www.shoottheapex.com
Keystone is offline   Reply With Quote
Old 10-14-2008, 07:58 PM   #2
Terrible1One3
n00b
 
Terrible1One3's Avatar
 
Joined: Jul 2006
Location: Thompsons Station, TN
Oddometer: 219
Terrible1One3 is offline   Reply With Quote
Old 10-14-2008, 08:04 PM   #3
Dert Gerl
Gnarly Adventurer
 
Joined: Aug 2007
Location: Prescott, AZ
Oddometer: 205
Is that part of the 600 mile "break" in?

It's not an off road bike if you don't have some JB Weld and zip ties holding a few things together!
__________________
2005 KTM 400exc
Dert Gerl is offline   Reply With Quote
Old 10-14-2008, 08:07 PM   #4
Keystone OP
Gnarly Adventurer
 
Joined: Jun 2008
Location: Lake Villa, IL
Oddometer: 201
Quote:
Originally Posted by Dert Gerl
Is that part of the 600 mile "break" in?

It's not an off road bike if you don't have some JB Weld and zip ties holding a few things together!
You got it. If I didn't intend to ride it I'd have spent the money on stocks! At least the 800 is holding its value better!
__________________
Cheers,
Tom
'09 F800GS (Yellow)
'05 F650GS (Sold)
'04 K1200RS (Sold)
'03 F650GS (Crashed)
(formerly hyperiate)

http://www.shoottheapex.com
Keystone is offline   Reply With Quote
Old 10-14-2008, 08:12 PM   #5
levity
nano-Adventurer
 
levity's Avatar
 
Joined: May 2004
Location: Irvine, Calif.
Oddometer: 1,088
Nice fix and write-up, Hyper one.
Thanks also for the heads-up.

I've seen the effects of a low speed left-side low-side on the street (very minor cosmetic damage), but this is the first I've seen on the right side.
Definitely a weak point! Sounds like crash bars really are needed.
levity is offline   Reply With Quote
Old 10-14-2008, 08:23 PM   #6
Gillies
Monkey Boy
 
Gillies's Avatar
 
Joined: May 2006
Location: Avondale, AZ
Oddometer: 732
Thanks for the write up.
__________________
What joins men together, he said, is not the sharing of bread but the sharing of enemies. -Judge Holden
Gillies is offline   Reply With Quote
Old 10-14-2008, 09:58 PM   #7
ABeef
Adventurer
 
Joined: Jul 2008
Location: Durango
Oddometer: 30
Would crash bars have prevented this damage?
__________________
2009 F800GS
ABeef is offline   Reply With Quote
Old 10-14-2008, 10:14 PM   #8
ALPHORN
Swiss
 
ALPHORN's Avatar
 
Joined: Oct 2008
Location: Lotus Land, Vancouver, Canada
Oddometer: 20
Talking good on you!

Judging from your experience and fixing abilities you seem very proud of that fix job... the biggest mistake you made is not falling off that bike but by purchasing a BMW, which actually stands for Badly Made Werke.... cheers
ALPHORN is offline   Reply With Quote
Old 10-14-2008, 10:28 PM   #9
Keystone OP
Gnarly Adventurer
 
Joined: Jun 2008
Location: Lake Villa, IL
Oddometer: 201
Quote:
Originally Posted by ABeef
Would crash bars have prevented this damage?
I think they likely would have, as long as they came up high enough.
__________________
Cheers,
Tom
'09 F800GS (Yellow)
'05 F650GS (Sold)
'04 K1200RS (Sold)
'03 F650GS (Crashed)
(formerly hyperiate)

http://www.shoottheapex.com
Keystone is offline   Reply With Quote
Old 10-14-2008, 10:28 PM   #10
Keystone OP
Gnarly Adventurer
 
Joined: Jun 2008
Location: Lake Villa, IL
Oddometer: 201
Quote:
Originally Posted by ALPHORN
Judging from your experience and fixing abilities you seem very proud of that fix job... the biggest mistake you made is not falling off that bike but by purchasing a BMW, which actually stands for Badly Made Werke.... cheers
Congratulations on your first post! I'm honored to have prompted it!
__________________
Cheers,
Tom
'09 F800GS (Yellow)
'05 F650GS (Sold)
'04 K1200RS (Sold)
'03 F650GS (Crashed)
(formerly hyperiate)

http://www.shoottheapex.com
Keystone is offline   Reply With Quote
Old 10-15-2008, 02:46 AM   #11
John in Leeds
Gnarly Adventurer
 
John in Leeds's Avatar
 
Joined: Jan 2007
Oddometer: 377
Quote:
Originally Posted by hyperiate
Congratulations on your first post! I'm honored to have prompted it!



John in Leeds is offline   Reply With Quote
Old 10-15-2008, 08:29 AM   #12
Toadride
Studly Adventurer
 
Toadride's Avatar
 
Joined: Jul 2008
Location: Done Roamin/Now Homin. Nelson BC
Oddometer: 827
I Like It!

Wow. Great photo essay, Hy. As for Badly Made, I figure the Beemer is no worse or better than any other bike. More complicated that my old KLR fer sure. But, I like a challenge. And at the price and with all the gadgets, I know I will be a little more careful with mine when it finally gets here. Plus I'll add all the protection I can for those nasty, delicate parts. But, thanks for the closeup looks.
Toadride is offline   Reply With Quote
Old 10-15-2008, 08:38 AM   #13
Dieselboy
Journey not Destination
 
Dieselboy's Avatar
 
Joined: Sep 2003
Location: Port of the Gasparilla
Oddometer: 1,122
Quote:
Originally Posted by levity
Nice fix and write-up, Hyper one.
Thanks also for the heads-up.

...... Sounds like crash bars really are needed.
+1
__________________
Dieselboy
~~~~~~~~~~~~~~~~~~~
The Adventure Continues
Dieselboy is offline   Reply With Quote
Old 10-15-2008, 08:59 PM   #14
PackMule
love what you do
 
PackMule's Avatar
 
Joined: Aug 2005
Location: New Hampshah
Oddometer: 19,460
Thanks for the post and pics.
__________________
Nate in N.E.

Yes, I have a Dakar problem -- that there are 50 weeks of the year without Dakar!

They don't expect you to finish. That's why it's the Dakar. -- PPiA
PackMule is offline   Reply With Quote
Old 10-16-2008, 05:18 AM   #15
Bigem
Beastly Adventurer
 
Bigem's Avatar
 
Joined: Aug 2007
Location: Qld
Oddometer: 2,545
I think crashbars are a "must have" on the 800. The best I have seen are the wildatheart out of South Africa, but freight and overall cost to Australia makes them prohibitive. The SW-motech crash bars look like a good thing too, don't come up as high as the w-a-h's but thats nothing that can not be fixed with some 20mm tube, a pipebender and a Mig welder!! Thats my plan, and they are on the way as I type. All I need is my 800!!
__________________
"I'm a thousand miles from nowhere,
Time don't matter to me,
Cause I'm a thousand miles from nowhere,
And there's no place I'd rather be!!
Bigem is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 02:18 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014