08 LT Overhaul Project - BMW Luxury Touring Community
 19Likes
  • 6 Post By saddleman
  • 3 Post By saddleman
  • 4 Post By saddleman
  • 1 Post By DanDiver
  • 1 Post By saddleman
  • 3 Post By saddleman
  • 1 Post By james216
 
LinkBack Thread Tools Display Modes
post #1 of 23 Old Apr 5th, 2020, 4:17 pm Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
08 LT Overhaul Project

Back in Sept. 2018 I bought a 2008 LT with 112,543 miles on it that the owner had started to part out. A hurricane was coming & it would have been completely flooded with salt water.

Since then I have been collecting the parts needed to repair and replace the needed parts to put it back together. I started working on it yesterday. After removing the body panels I washed & degreased everything.

I hope to finish it by the end of July. I have a buyer for it if it is ready the first of August. Because it will take awhile I hung the body panels up on the wall in my shop.

I'll try to document with pictures as I go along. First up check the engine. Today I checked valve lash, cranking compression & cylinder leak down.

There are four intake valves under the lash spec. & I'll try & set the lash on the loose side on all of the valves. The compression & leak down were great.
Attached Thumbnails
Click image for larger version

Name:	08 LT Project 003.JPG
Views:	55
Size:	1.13 MB
ID:	156345   Click image for larger version

Name:	08 LT Project 002.JPG
Views:	54
Size:	1.35 MB
ID:	156347   Click image for larger version

Name:	08 LT Project 011.JPG
Views:	58
Size:	1.01 MB
ID:	156349   Click image for larger version

Name:	08 LT Project 005.JPG
Views:	59
Size:	1.10 MB
ID:	156351   Click image for larger version

Name:	08 LT Project 006.JPG
Views:	57
Size:	1.08 MB
ID:	156353  

Click image for larger version

Name:	08 LT Project 008.JPG
Views:	57
Size:	1.37 MB
ID:	156355   Click image for larger version

Name:	08 LT Project 009.JPG
Views:	54
Size:	1.25 MB
ID:	156357   Click image for larger version

Name:	08 LT Project 010.JPG
Views:	55
Size:	1.38 MB
ID:	156359  

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
Sponsored Links
Advertisement
 
post #2 of 23 Old Apr 5th, 2020, 4:26 pm Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

This bike was on a home on the Intercoastal water way in North Carolina. It had the wrong spark plugs in it and the spark plug wires did not grip the plugs tight. The corrosion from the salt air is evident in these pictures because the contact wasn't like it would have been with the proper spark plugs.
Attached Thumbnails
Click image for larger version

Name:	08 LT Project 004.JPG
Views:	54
Size:	940.4 KB
ID:	156361   Click image for larger version

Name:	08 LT Project 007.JPG
Views:	46
Size:	894.7 KB
ID:	156363  

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
post #3 of 23 Old Apr 6th, 2020, 11:44 am
Senior Member
 
james216's Avatar
 
Join Date: Jan 2013
Location: Garfield Hts, Ohio, USA
Posts: 1,482
Re: 08 LT Overhaul Project

Oh yea. I see the plug tips. Well. Nice project though.

2004 K1200LT. Big Mama
1999 Suzuki Intruder VL1500LC. Betty Lou.
I'm a 4 percenter.
james216 is offline  
 
post #4 of 23 Old Apr 8th, 2020, 9:06 am Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

It has a failed ABS unit the rear servo does not work. Yesterday I installed new Speigler brake lines. I flushed the whole system with over a quart of new brake fluid. I wanted to get all of the old fluid & the small rubber brake line particles out before I install the next ABS unit.

I used a syringe to refill the brake system. I was able to power bleed the front brakes but I had to vacuum bleed the rear brake. I have a full size battery hooked up while I'm working on the bike.

It also needs a clutch & maybe a transmission I'll remove the trans. today.
Attached Thumbnails
Click image for larger version

Name:	08 LT Project 021.JPG
Views:	48
Size:	1.29 MB
ID:	156421   Click image for larger version

Name:	08 LT Project 020.JPG
Views:	52
Size:	1.15 MB
ID:	156423   Click image for larger version

Name:	08 LT Project 015.JPG
Views:	48
Size:	1.37 MB
ID:	156425   Click image for larger version

Name:	08 LT Project 016.JPG
Views:	55
Size:	1.05 MB
ID:	156427   Click image for larger version

Name:	08 LT Project 022.JPG
Views:	50
Size:	989.2 KB
ID:	156429  

Click image for larger version

Name:	08 LT Project 026.JPG
Views:	49
Size:	1.08 MB
ID:	156431   Click image for larger version

Name:	08 LT Project 025.JPG
Views:	48
Size:	1.28 MB
ID:	156433   Click image for larger version

Name:	08 LT Project 028.JPG
Views:	45
Size:	1.41 MB
ID:	156435  
meese, Patric and bmwcoolk1200 like this.

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
post #5 of 23 Old Apr 10th, 2020, 7:37 pm Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

I didn't get to work on it again until this afternoon. I found a squirrel nest under my deck between the deck & the sealed off surface underneath the deck. I got the throttle body & transmission removed today.

Because I'll be removing the camshafts while the clutch is removed I made a crankshaft lock so nothing can turn over while the camshafts are removed. I welded a 1/4 x 20 nut to two cut off spark plugs so I can keep the crankshaft locked up. I have the pistons locked up close to the half way down point so I can rotate the camshafts and the valves will not contact the pistons.
Attached Thumbnails
Click image for larger version

Name:	08 LT Project 049.JPG
Views:	42
Size:	1.33 MB
ID:	156495   Click image for larger version

Name:	08 LT Project 038.JPG
Views:	43
Size:	974.3 KB
ID:	156497   Click image for larger version

Name:	08 LT Project 039.JPG
Views:	38
Size:	1.29 MB
ID:	156499   Click image for larger version

Name:	08 LT Project 041.JPG
Views:	39
Size:	1.36 MB
ID:	156501  
Patric, sailor, RockyRoad and 1 others like this.

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
post #6 of 23 Old Apr 10th, 2020, 7:49 pm
Senior Member
 
Join Date: Dec 2017
Location: Brisbane Australia
Posts: 394
Re: 08 LT Overhaul Project

That's very innovative of you. I love hard work , I could watch it all day.
Wazza is offline  
post #7 of 23 Old Apr 11th, 2020, 7:41 am
Lifetime Supporter
 
DanDiver's Avatar
 
Join Date: Jun 2003
Location: Tampa, FL, USA
Posts: 4,856
Re: 08 LT Overhaul Project

Thanks for sharing the pictures.... To anyone who has never seen you travel, all of the tools in the pictures are part of every trip except for the lift :-). Someone will be getting a great bike..
Patric likes this.

Dano
Tampa, Fl.

12 K1600 GTL
02 K1200 LT (gone but not forgotten)
DanDiver is offline  
post #8 of 23 Old Apr 12th, 2020, 6:20 pm Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

Yesterday I remove the transmission, clutch assembly & camshafts. I'll need 8 new shim buckets. I ordered the clutch parts & shim buckets from MotoBins. The clutch disc shows 50% wear. Today I cleaned parts all day.

The throttle body was first because of the split vent tube it was messy. Next was the clutch housing.
Attached Thumbnails
Click image for larger version

Name:	08 LT Project 059.JPG
Views:	31
Size:	1.29 MB
ID:	156539   Click image for larger version

Name:	08 LT Project 050.JPG
Views:	33
Size:	1.57 MB
ID:	156541   Click image for larger version

Name:	08 LT Project 053.JPG
Views:	32
Size:	1.36 MB
ID:	156543   Click image for larger version

Name:	08 LT Project 054.JPG
Views:	30
Size:	1.15 MB
ID:	156545   Click image for larger version

Name:	08 LT Project 055.JPG
Views:	28
Size:	1.25 MB
ID:	156547  

Click image for larger version

Name:	08 LT Project 056.JPG
Views:	28
Size:	1.25 MB
ID:	156549   Click image for larger version

Name:	08 LT Project 061.JPG
Views:	31
Size:	1.37 MB
ID:	156551   Click image for larger version

Name:	08 LT Project 060.JPG
Views:	28
Size:	1.27 MB
ID:	156553  
Patric likes this.

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
post #9 of 23 Old Apr 12th, 2020, 6:27 pm Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

The transmission appears to be fine. I think his shifting problem was in the dry shift linkage. I cleaned it today installed new seals & pressure checked it at 5 psi before & after I installed the seals. Next I ground a drain slot in the slave cylinder housing. The fuel injectors go out tomorrow for rebuild.
Attached Thumbnails
Click image for larger version

Name:	08 LT Project 063.JPG
Views:	40
Size:	1.32 MB
ID:	156555   Click image for larger version

Name:	08 LT Project 064.JPG
Views:	38
Size:	1.52 MB
ID:	156557   Click image for larger version

Name:	08 LT Project 065.JPG
Views:	34
Size:	952.3 KB
ID:	156559   Click image for larger version

Name:	08 LT Project 067.JPG
Views:	35
Size:	1.07 MB
ID:	156561  

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Last edited by saddleman; Apr 12th, 2020 at 6:34 pm.
saddleman is offline  
post #10 of 23 Old Apr 12th, 2020, 7:37 pm
Senior Member
 
Join Date: Dec 2017
Location: Brisbane Australia
Posts: 394
Re: 08 LT Overhaul Project

I love to see these great bikes being kept on the road. My Wife would not be happy if I used her muffin trays to work on my bike however.
Wazza is offline  
post #11 of 23 Old Apr 12th, 2020, 9:07 pm
Wrencher Extraordinaire
 
jzeiler's Avatar
 
Join Date: May 2004
Location: Hazel Green, AL, USA
Posts: 13,661
Re: 08 LT Overhaul Project

Dave do you over fill the transmission for the pressure test? I have found that Ferrero Rocher 48 piece box perfect for valve jobs on the LT as it hold the buckets, valve springs and keepers in a dust free way.
Attached Thumbnails
Click image for larger version

Name:	Nice dust proof holder.png
Views:	32
Size:	572.8 KB
ID:	156563  

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 114 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

Have ridden a Motorcycle in all 48
But lack DE, MA, RI and CT with the 2005 LT

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
jzeiler is offline  
post #12 of 23 Old Apr 12th, 2020, 9:07 pm
Senior Member
 
bmwcoolk1200's Avatar
 
Join Date: Feb 2015
Posts: 4,195
Re: 08 LT Overhaul Project

Quote:
Originally Posted by saddleman View Post
Next I ground a drain slot in the slave cylinder housing.
Interesting variation on the slave weep hole. How long have you been doing the grinding versus drilling?

Gordon
Sugar Hill, GA
2001 K1200LTI – Champagne (current ride) Lazy Susan
1998 R1100RT – Never should have sold it
1974 Yamaha TX 750 Twin. Omni Phase Balanced


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
bmwcoolk1200 is offline  
post #13 of 23 Old Apr 13th, 2020, 3:12 am Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

Quote:
Originally Posted by jzeiler View Post
Dave do you over fill the transmission for the pressure test? I have found that Ferrero Rocher 48 piece box perfect for valve jobs on the LT as it hold the buckets, valve springs and keepers in a dust free way.
The transmission is drained & I spray soapy water on it looking for air bubbles.

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
post #14 of 23 Old Apr 13th, 2020, 3:14 am Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

Quote:
Originally Posted by bmwcoolk1200 View Post
Interesting variation on the slave weep hole. How long have you been doing the grinding versus drilling?
This is the second one I have done. I had a slave seal leak & the drain hole did not keep the gear oil from entering the clutch area.

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
post #15 of 23 Old Apr 13th, 2020, 9:42 am
Senior Member
 
bmwcoolk1200's Avatar
 
Join Date: Feb 2015
Posts: 4,195
Re: 08 LT Overhaul Project

Quote:
Originally Posted by saddleman View Post
This is the second one I have done. I had a slave seal leak & the drain hole did not keep the gear oil from entering the clutch area.
I never expected the weep hole to protect the clutch but hopefully give some advanced notice of a leak in that area with a drip to investigate. Maybe it just isn't large enough to allow that to happen.

Gordon
Sugar Hill, GA
2001 K1200LTI – Champagne (current ride) Lazy Susan
1998 R1100RT – Never should have sold it
1974 Yamaha TX 750 Twin. Omni Phase Balanced


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
bmwcoolk1200 is offline  
post #16 of 23 Old Apr 13th, 2020, 9:42 am
Member
 
Join Date: Mar 2020
Posts: 87
Dave. Do you think you could put some sizes on your picture of ‘customized’ wrenches. I am a newbie and I am doing a fairly extensive overhaul of a 2005 and I like to be ready.
David Yerema is offline  
post #17 of 23 Old Apr 13th, 2020, 3:55 pm Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

Quote:
Originally Posted by David Yerema View Post
Dave. Do you think you could put some sizes on your picture of ‘customized’ wrenches. I am a newbie and I am doing a fairly extensive overhaul of a 2005 and I like to be ready.
Most of my bent wrenches are 7 mm for bleeding & flushing the brakes on the ABS pumps. My 8 mm wrenches are for checking & tightening the ball studs on the shift linkage. My 10 mm wrench is to hold the nut on the shifter jack shaft.

My suggestion would be to purchase inexpensive wrenches in different lengths & heat them to bend them as needed.

I also have 10 mm & 11 mm wrenches that have been narrowed & bent to give clearance on the brake calipers for the hose that goes over the bleeder valve when bleeding or flushing.

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
post #18 of 23 Old Apr 13th, 2020, 4:20 pm Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

I'm back to work tomorrow. Today most of it was cleaning up from last nights storm. I did manage to clearance the swing arm for the Metzler 888 that was on the bike that had one extra shim. I removed the casting line where the tire could rub. After grinding I cleaned & painted the area.
Attached Thumbnails
Click image for larger version

Name:	08 LT Project 068.JPG
Views:	32
Size:	1.24 MB
ID:	156565   Click image for larger version

Name:	08 LT Project 070.JPG
Views:	31
Size:	1.71 MB
ID:	156567   Click image for larger version

Name:	08 LT Project 071.JPG
Views:	32
Size:	1.06 MB
ID:	156569   Click image for larger version

Name:	08 LT Project 072.JPG
Views:	30
Size:	1.24 MB
ID:	156571   Click image for larger version

Name:	08 LT Project 073.JPG
Views:	29
Size:	1.30 MB
ID:	156573  

Click image for larger version

Name:	08 LT Project 076.JPG
Views:	28
Size:	1.42 MB
ID:	156577  
Patric, bmwcoolk1200 and kbob12 like this.

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
post #19 of 23 Old Apr 14th, 2020, 12:40 am
Member
 
Join Date: Sep 2008
Location: Redlands, CA, United States
Posts: 86
Cool Re: 08 LT Overhaul Project

Quote:
Originally Posted by jzeiler View Post
Dave do you over fill the transmission for the pressure test? I have found that Ferrero Rocher 48 piece box perfect for valve jobs on the LT as it hold the buckets, valve springs and keepers in a dust free way.
Plus, you have to eat the chocolate first, before you can use the tray!
djmellor is offline  
post #20 of 23 Old Apr 14th, 2020, 12:51 pm
Senior Member
 
james216's Avatar
 
Join Date: Jan 2013
Location: Garfield Hts, Ohio, USA
Posts: 1,482
Re: 08 LT Overhaul Project

That's a lot of work Dave. Someone's getting a great bike.. Where did you get a new ABS pump?

2004 K1200LT. Big Mama
1999 Suzuki Intruder VL1500LC. Betty Lou.
I'm a 4 percenter.
james216 is offline  
post #21 of 23 Old Apr 14th, 2020, 6:11 pm Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

Quote:
Originally Posted by james216 View Post
That's a lot of work Dave. Someone's getting a great bike.. Where did you get a new ABS pump?
The replacement ABS pump is off of a 2005 LT with about 85,000 miles on it.

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
post #22 of 23 Old Apr 15th, 2020, 7:14 pm
Senior Member
 
james216's Avatar
 
Join Date: Jan 2013
Location: Garfield Hts, Ohio, USA
Posts: 1,482
Re: 08 LT Overhaul Project

Too bad the servo assist can't be rebuilt. Well at least not reasonably anyways.The cost outweighs the bikes value.
Patric likes this.

2004 K1200LT. Big Mama
1999 Suzuki Intruder VL1500LC. Betty Lou.
I'm a 4 percenter.
james216 is offline  
post #23 of 23 Old Apr 16th, 2020, 11:16 am Thread Starter
Enjoy The Ride
 
saddleman's Avatar
 
Join Date: Sep 2008
Location: Huntersville, NC, USA
Posts: 3,957
Re: 08 LT Overhaul Project

Quote:
Originally Posted by james216 View Post
Too bad the servo assist can't be rebuilt. Well at least not reasonably anyways.The cost outweighs the bikes value.
If I hadn't found a good used ABS unit I would have parted the bike out.

Dave Selvig
2004 Black LT
2000 Canon Red LT



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
saddleman is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the BMW Luxury Touring Community forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may 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 Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome