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Old 11-09-2012, 02:39 AM   #1
PlecoLB OP
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Location: Cape Town RSA
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Cry Rattle noise at about 4000RPM to 3800 RPM while coasting. (found the source)

Hello Guys.

I own a high mileage 2005 GS1200. It has done about 150 000kms so far and counting.

When I bought it, it had a high pitched rattle noise at about 4000RPM while cruising / coasting. Its gone under power.

I now have what I can only describe as a stretched chain noise from low revs all the way up while coasting / cruising. Gone when I pull the clutch and drop the revs while rolling.

I am not sure at what intervals the chains / chain guides/ chain tensioners need to be replaced. Cannot get a lot of info out there, as there seems to be only a few 2005 and on models with this high mileage.

Any ideas?
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Riding a block of flats in the sand is quite fun!
(Previous bike: Kawasaki KLR 650: The Art of Arriving)

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Old 11-09-2012, 02:40 AM   #2
PlecoLB OP
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OK, just came back from an independent BMW mecchie. It seems that all 3 chains are rattling.

Cannot see whats wrong until I open up though. I really hope that it is only worn chain guides and tensioners.

Still a big job coming up though.

Any body done this before?

Thanks.
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Riding a block of flats in the sand is quite fun!
(Previous bike: Kawasaki KLR 650: The Art of Arriving)
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Old 11-09-2012, 02:41 AM   #3
PlecoLB OP
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Hello There.

Well, the rattle turned to a clatter, and I decided to rather pull the left side cylinder off to inspect.

So far, visually, everything almost look like new. The honing marks are even still visible in the sleeve.

The only wear I can see is on the small end bearings. I could not pic the other side, but it has the same bald spot directly opposite the I am not sure if this would cause the racket I was hearing.

Any input here from guys with engine experience.

Bald spot on both sides



Other items with veryu little wear and carbon





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Pleco.

Riding a block of flats in the sand is quite fun!
(Previous bike: Kawasaki KLR 650: The Art of Arriving)
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Old 11-09-2012, 02:42 AM   #4
PlecoLB OP
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Hello There.

It just got a lot worse last night. :mad:

I decided to pull the conrods to see the condition of the big end bearings. (by the way, the conrods have a funny way of joining. see pics)

This is what I found:



And this:



The one set of bearings was turning between the conrod and crank. Here is the conrod. Note the mating faces.



Here are pics of the 2 crank journals:



and



I will be pulling the whole motor tomorrow night, to see what else has gone wrong.

At this stage it seems that rebuilding the motor is not a viable financial option.

Do any of you lot know of a salvage yard on your side of the pond where I can get pricing on a reasonable low mileage recovered engine please?
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Pleco.

Riding a block of flats in the sand is quite fun!
(Previous bike: Kawasaki KLR 650: The Art of Arriving)

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Old 11-09-2012, 02:43 AM   #5
PlecoLB OP
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OK, the decision was made that I need to get that crank out, and inspect the rest of the insides.

This was getting very daunting. The motor is the main frame, so the front and the back of the bike needs to unbolted from it.

All wiring harnesses, pipes and cables needed to be separated as well.











All I can say is that the REPROM is absolutely indispensible.
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Pleco.

Riding a block of flats in the sand is quite fun!
(Previous bike: Kawasaki KLR 650: The Art of Arriving)

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Old 11-09-2012, 02:43 AM   #6
PlecoLB OP
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Now that we had the motor out, stripping it down was the next step.

2 things that were tricky here, was the removal of the timing cover, and pulling the crank pulley. Had to amke a few plans, and also had to heat up the crank pulley to get it loose.

Motor in halves:



Left half


Right half


Worst main bearing


Oil pump housing has seen a bit of scouring, and will probably need replacing.




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Pleco.

Riding a block of flats in the sand is quite fun!
(Previous bike: Kawasaki KLR 650: The Art of Arriving)

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Old 11-09-2012, 02:47 AM   #7
PlecoLB OP
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Got some good news for a change.

The crank has been polished. The marks on it were pieces of big ends stuck to the surface.

Pistons and sleeves are all in tolerance. I would just put new rings in while I am in this far.

So, it seems costs are down to gaskets, seals, main bearings and conrods. Still need to have the oil pump checked.

Feeling a little better now.
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Pleco.

Riding a block of flats in the sand is quite fun!
(Previous bike: Kawasaki KLR 650: The Art of Arriving)

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Old 11-09-2012, 08:24 AM   #8
dede
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Quote:
Originally Posted by PlecoLB View Post
Got some good news for a change.

The crank has been polished. The marks on it were pieces of big ends stuck to the surface.

Pistons and sleeves are all in tolerance. I would just put new rings in while I am in this far.

So, it seems costs are down to gaskets, seals, main bearings and conrods. Still need to have the oil pump checked.

Feeling a little better now.
How far out of tolerance are the connecting rods? Are you sure they don't just have the same deposits as the crank?
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Old 11-09-2012, 08:30 AM   #9
PlecoLB OP
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Unfortunately the big end bearing turned inside the one conrod.
And both small ends have bald spots. Bmw does not sell the small end bushes separately only complete on conrod.

There are some pics of the small end bearings and conrod wear.
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Riding a block of flats in the sand is quite fun!
(Previous bike: Kawasaki KLR 650: The Art of Arriving)
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Old 11-09-2012, 09:18 AM   #10
Wy'east
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Quote:
Originally Posted by PlecoLB View Post
...I would just put new rings in while I am in this far...
How much further could you go? Unlacing the wheels maybe... Seriously though, good job so far and thanks for posting the pictures. Any idea what might have contributed or helped along this situation in the first place?
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Old 11-09-2012, 09:31 AM   #11
PlecoLB OP
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Overheating maybe, running while on its site etc. A lot of small things all adding up.

I'll post a pic of the previous rider in action. The bike was fully utilized.
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Riding a block of flats in the sand is quite fun!
(Previous bike: Kawasaki KLR 650: The Art of Arriving)
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Old 11-09-2012, 10:39 AM   #12
FireDog45
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It's called Fracture Splitting.

According to SAE:

"Fracture split steel connecting rod has been developed for new passenger diesel engines for its advantages in cost saving and better performance. The splitting type of steel con rod is made of high carbon micro-alloyed steel with no additional heat treatment after hot forging. This con rod blank is forged in one-die mold and later fracture splitted. Unlike the conventional types where the rods and caps are separately forged and machined, this steel split con rod needs no additional rod/cap contact face milling which means a substantial savings in machining cost. Besides, a firm contact between rod and cap improves stiffness and compatibility with other crank-train moving parts - a definite merit in engine performance."

Quote:
Originally Posted by PlecoLB View Post
Hello There.

It just got a lot worse last night. :mad:

I decided to pull the conrods to see the condition of the big end bearings. (by the way, the conrods have a funny way of joining. see pics)

The one set of bearings was turning between the conrod and crank. Here is the conrod. Note the mating faces.

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Old 11-09-2012, 10:58 AM   #13
scooteraug02
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Quote:
Originally Posted by PlecoLB View Post
The bike was fully utilized.
I like that expression. Same as "Ran the piss out of it"



What are the vertical scars? Those are ok? Are the BMW cylinders Nicasil coated?

Awesome pictures. Don't stop. It's nice to see the inside of the engine.
Step by step reassembly would be even more awesome.
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Old 11-09-2012, 11:13 AM   #14
SafetyFish
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Cool2

So, how did the previous owner "utilize" the bike?
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Old 11-09-2012, 11:50 AM   #15
Wallowa
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My Question Also

Quote:
Originally Posted by SafetyFish View Post
So, how did the previous owner "utilize" the bike?
First kudos to you for your tenacity and spirit in digging into and repairing your bike!

As an owner...my first thought was "what the hell went wrong and caused that!" Your thoughts and analysis would be greatly appreciated.

Thanks.
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