I bought an 05' with 98k miles as a project bike, it's my 3rd k1200lt. I bought the bike knowing it needed a clutch. The previous owner had started to replace the clutch, but barely got past the skin during the surgery before he realized he was in way over his head. I bought the bike on the cheap, and bought a 2003 parts bike the following week when I picked up a new Odyssey battery I had purchased from a local guy off of eBay.
I disassembled the parts bike to get the new clutch (2k mi) from it, along with copious accessories I'll be using on the 05'.
I just got to the clutch on the 05', and realize the clutch still isn't really that worn, but the rear main seal has failed, 2 of 3 transmission seals are leaking, and it looks like the clutch slave cylinder is leaking as well.
I've read that a new clutch plate is 6 mm thick is this true?
I plan to use the nearly new clutch plate from the 03', but would the clutch plate that has been saturated in oil be of any use perhaps at a later date if it were cleaned (presumably with brake clean)?
Where can I purchase the seals that I need? I believe that I want the Viton variety.
Can the slave cylinder be rebuilt, or does it have to be replaced?
Also the sprag gear is apparently gummed up, I've read that they should be replaced, not cleaned, does anyone have a materials/parts list for this task?
Both bikes have well documented maintenance history most of which was done by bmw dealerships, other than some oil/air filter changes.
The 05' has a k & n (lifetime) air filter any thoughts about whether I should keep the k&n, or use the oem paper filter?
Any help is much appreciated! Dale
Hey dale, Let me answer a couple of your questions.
1. Yes, the new thickness of a friction disk is 6mm
2. I have not read of anyone suffering a slave or O-ring failure to reuse a saturated OEM friction disk. They are porous and getting all the oil out would be difficult at best and with the work involved, I don't think i ahve read of anyone who has taken that chance. They also wear in a dish pattern so old and old would be a bad combination if they were not worn that way together. They just replace without a second thought. If the hard parts are not worn, they can be cleaned sufficiently and used with a new friction disk.
3. The seals you need can be found on MAX BMW. There are parts lists on several threads. I don't have one handy to post but they are not hard to locate and confirm current number and price on MAX.
If you want the Viton 19x4 O-ring which I think most here would strongly recommend over the OEM, you can PM me with your address and I will drop one in the mail or you can find them online with a search. I have a few spares from my order of a bag of 10.
4. There is no current rebuild kit for the slave cylinder i have heard or read about so buy new from Beemer boneyard. About $60 cheaper and IS the OEM replacement from the manufacturer while they last. Once gone, they will be dealer only.
5. Haven't messed with the sprag gear yet so no help there.
6. There are several threads dealing with the K&N filter. Most here will opt for the paper filter over the K&N siting less dirt through and more protection of the nikasil coating of the cylinders.