Take a trip down the dark...dark rabbit hole... - BMW Luxury Touring Community
 
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post #1 of 40 Old Sep 23rd, 2010, 7:08 pm Thread Starter
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Take a trip down the dark...dark rabbit hole...

With the recent additions (or implants ) to Barbara a while ago, it would seem that she needs a heart transplant as well. This will be her second transplant to ensure she keeps her skirt on!!!

That said, I have the donor engine...

And have done my own clutch/gearbox (i.e. -Implants) but never had the need or the want to tackle a job like this myself. I've got the tools, and most of the knowledge to get this done.

I would however like the input from those that have completed the task, if there are any pit falls to look at prior? Barbara has 148K on an engine that was replaced already. I believe that I blew out a cylinder ring as she is smoking paul mauls, mixed with oil! In the last few hundred miles she has went through about a quart of oil!!1

I will post pictures of the ordeal for the humor value only!

Hoss
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post #2 of 40 Old Sep 23rd, 2010, 8:29 pm
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Re: Take a trip down the dark...dark rabbit hole...

Go for it Hoss! We're rootin' for ya!



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post #3 of 40 Old Sep 23rd, 2010, 8:38 pm
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Re: Take a trip down the dark...dark rabbit hole...

Wow,how many miles are on the bike total?

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post #4 of 40 Old Sep 23rd, 2010, 9:13 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by clayton
Wow,how many miles are on the bike total?
Somewhere in the range of 148K, I do not suspect that the odometer has been swapped out... You figure that grifscoots, RaffyK, Scott H (not on the site) and I rode/ride her hard... all these years!

Anyone go down this hole? complete a swap? need to know if there is anything I should watch for or any special tips....

Hoss
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post #5 of 40 Old Sep 24th, 2010, 8:16 am
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by shoswell
Somewhere in the range of 148K, I do not suspect that the odometer has been swapped out... You figure that grifscoots, RaffyK, Scott H (not on the site) and I rode/ride her hard... all these years!

Anyone go down this hole? complete a swap? need to know if there is anything I should watch for or any special tips....
When it's all back together, don't forget to add oil. Don't ask me why . . .

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post #6 of 40 Old Sep 24th, 2010, 12:31 pm
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Re: Take a trip down the dark...dark rabbit hole...

All the best to you for tackling this Hoss. Let us know how it goes.

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post #7 of 40 Old Sep 24th, 2010, 2:32 pm
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Re: Take a trip down the dark...dark rabbit hole...

What year was the donor bike? Differences in ECU for the 99-04 and 05 and newer?

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post #8 of 40 Old Sep 24th, 2010, 2:43 pm
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Re: Take a trip down the dark...dark rabbit hole...

Just make sure that you get all the electrical wiring undone at the right places before you drop the motor, including the three wires at the front of the engine. John Zeiler and I just finished this transplant on my '02 in July.

As another has said, what year motor do you have going in what year frame? If the donor motor is '05 and up and the bike is '04 on down, you WILL need a new ECU (moronic) for your bike. The '05 and up have a different cam sprocket and there for different timing from the ECU.

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post #9 of 40 Old Sep 24th, 2010, 7:31 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by Steve_R
Just make sure that you get all the electrical wiring undone at the right places before you drop the motor, including the three wires at the front of the engine. John Zeiler and I just finished this transplant on my '02 in July..
Found that in the tear down of the donor bike. Never knew there were wires comming from the block... Who knew!!!

Quote:
Originally Posted by Steve_R
As another has said, what year motor do you have going in what year frame? If the donor motor is '05 and up and the bike is '04 on down, you WILL need a new ECU (moronic) for your bike. The '05 and up have a different cam sprocket and there for different timing from the ECU.
The donor is an 01, and Barbara is an 00. I will be reusing the motronic as its got the rhinewest chip in it.. Hopefully its as straight forward as the tear down of the donor bike... If so I's think its going to be tit;s up my monday...

This is where I am at today... Tear down starts tomarrow... We will see how far I get...Just put on the stand and losened the swing arm bolts!!





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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
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post #10 of 40 Old Sep 24th, 2010, 9:20 pm
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Re: Take a trip down the dark...dark rabbit hole...

The oil pressure and water temp sending wires as well as the hall effect wires come out at the top of the timing cover and disconnect in the lower relay box. Plug and play if you get it right. I made a wooden plate with angle stock that bolted to the four holes in the side of the oil pan (the skid plate mounts to the rear holes).

This wooden plate was then bolted to a floor jack and with the engine mounted it was really easy to raise the engine/trans assy. I had the back of the bike raised up and put 1/4 inch bolts in the front two motor mounts to give me some swinging room at the tranny as I lowered the frame down on it. I recommend pulling the TBs off for this. Just gives you one less thing to worry about, but don't forget to put them back on and route the breather hose before you put in the rear mount bolt.
You have been there before since have done a clutch job , then you were only two bolts and three wires away from an engine change.

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post #11 of 40 Old Sep 25th, 2010, 8:09 am Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by jzeiler
I made a wooden plate with angle stock that bolted to the four holes in the side of the oil pan (the skid plate mounts to the rear holes).



Thanks, I was hoping you would chime in... So, if i read correctly, the biggest beo'tch is going to get the new in the old position? kinda thought that...

Slow and methodical..... should help....

Hoss
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post #12 of 40 Old Sep 25th, 2010, 9:35 am
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Re: Take a trip down the dark...dark rabbit hole...

OK OK here are the pic's. I took out the cup in the jack and bolted a 2 x 4 to it. Then I screwed a plywood plate to the 2 x 4. I jacked the thing up under the engine I was removing and mounted the angle stock with M8 bolts to the oil pan and then marked the plywood for mounting the angle stock . Drilled the holes and bolted it all up. This will be a little harder to do on a lift. I was on the floor when we did Steve's bike.
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John
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post #13 of 40 Old Sep 25th, 2010, 10:41 am Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Good to know.. I may just try to manhandle if possible... You know how us Marines are when it comes to brut force!

Started about 7am PST... Wife is stopping me, to feed me... so after 1.5 hours....





More to follow!
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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
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post #14 of 40 Old Sep 25th, 2010, 12:16 pm
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Re: Take a trip down the dark...dark rabbit hole...

You could man handle it if you get the tranny off and have a helper. I choose the jack method to make the single handed removal easier for me. Press on and Semper Fi, Hoss! Wish I could be there to lend a hand.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 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

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post #15 of 40 Old Sep 25th, 2010, 12:39 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by jzeiler
You could man handle it if you get the tranny off and have a helper. I choose the jack method to make the single handed removal easier for me. Press on and Semper Fi, Hoss! Wish I could be there to lend a hand.

As do I, seems my group of support chose to go on a week long ride on Friday! Harrumph!!!

I'm taking my second break... another 1.5 and this is where I be!




I think this was a sign that something was wrong. Ya think?





At this point I've got to dig into the books to find out how to detach the cruise control and throttle cable...




Boldly going where I've never been before....Scaaaarrrrrryyyyy!
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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
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post #16 of 40 Old Sep 25th, 2010, 2:22 pm
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Re: Take a trip down the dark...dark rabbit hole...

The pics are great - I'm realy enjoying your adventure into the unknown.
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post #17 of 40 Old Sep 25th, 2010, 3:21 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by BigGeo
The pics are great - I'm realy enjoying your adventure into the unknown.
My pleasure... Sorry for the delay, but you know what happens when neighbors stop by... Should have been at the assembly stage by now...

On a side note: throttle and cruise were a little tricky, but I did not need to refer to the book. You see, I can not read!

Also, the block itself is not heavy... but then being 6'5 260lbs helps!









Now for the UGLY pictures....







And the puzzling Back side of the gear box!


Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
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post #18 of 40 Old Sep 25th, 2010, 3:30 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Time for lunch! which leaves time to think...

Crap all that has to be put back on ????



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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
'05- K1200LT - Gretchen
R.I.P. - '00- K1200LTE- "Barbara" - Retired at 168K 9/2011
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post #19 of 40 Old Sep 25th, 2010, 5:15 pm
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by shoswell
My pleasure... Sorry for the delay, but you know what happens when neighbors stop by... Should have been at the assembly stage by now...

On a side note: throttle and cruise were a little tricky, but I did not need to refer to the book. You see, I can not read!

Also, the block itself is not heavy... but then being 6'5 260lbs helps!









Now for the UGLY pictures....







And the puzzling Back side of the gear box!



Strange, I could see your other pics, but I can't see those in this post.

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post #20 of 40 Old Sep 25th, 2010, 5:18 pm
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Re: Take a trip down the dark...dark rabbit hole...

Hoss, it's been almost 2 hours since your last report. Ya got 'er back together yet?

Loren

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post #21 of 40 Old Sep 25th, 2010, 8:48 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by wa1200lt
Hoss, it's been almost 2 hours since your last report. Ya got 'er back together yet?

Loren

Yip, stopped at 5 to clean up and make a run to the auto parts store for some odds and ends. A little tricky connecting everything, electical and fuel rail/injectors but it all seems good to go! Engine is hanging free from support, just a little left to go.. calling it quits for the night....

To be continued tomarrow! You can tell by the condition of my work area, that I'm spent!




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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
'05- K1200LT - Gretchen
R.I.P. - '00- K1200LTE- "Barbara" - Retired at 168K 9/2011
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post #22 of 40 Old Sep 25th, 2010, 8:52 pm
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Re: Take a trip down the dark...dark rabbit hole...

Wow that was fast Hoss. Looks like the breather tube was shot on Barbara's old heart. That thing can make quite a mess. At the rate you are going you'll be test driving her tomorrow.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 K and counting...
2006 Bushtec Turbo+2 Spell
2004 330 Ci Convertable
K4AN

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But lack DE, MA, RI and CT with the 2005 LT

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post #23 of 40 Old Sep 26th, 2010, 4:08 am Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

The kids were watching some, well kids movie so I went out and tinkered a bit... Took care of some wireing issues (cleaned up my last farkle) and put the radiators back as well as the air box...

Well took the air box back off because the throttle sticks... Routing issue I would assume. Anyone care to venture a guess as to the correct routing?







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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
'05- K1200LT - Gretchen
R.I.P. - '00- K1200LTE- "Barbara" - Retired at 168K 9/2011
MOA, IBA, EXR & RCB and TMI
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post #24 of 40 Old Sep 26th, 2010, 8:08 am
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by shoswell
The kids were watching some, well kids movie so I went out and tinkered a bit... Took care of some wireing issues (cleaned up my last farkle) and put the radiators back as well as the air box...

Well took the air box back off because the throttle sticks... Routing issue I would assume. Anyone care to venture a guess as to the correct routing?
Wonder if this might help, Hoss. Hope it does. Good luck.
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post #25 of 40 Old Sep 26th, 2010, 9:54 am
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Re: Take a trip down the dark...dark rabbit hole...

Looks like you have cables routed right Hoss. Double check the clamps on the TBs for interference with the throttle function.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 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

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post #26 of 40 Old Sep 26th, 2010, 11:00 am Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Double check the ""clamps""?
The air box is the only thing with clamps? am I dense or ??? the cables stick even with the AB off..... Harrumph!

p.s.- Thanks Dick!

Hoss
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post #27 of 40 Old Sep 26th, 2010, 12:59 pm
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Re: Take a trip down the dark...dark rabbit hole...

Hoss:

Good work and thanks for sharing.

It as mentioned to check clamps. I replaced the breather hose on mine last winter. That is the part they start with and build the bike around it. Check throttle range, a lot of small parts in close proximity to each other, some of them need to move, a clamp placed so its easy to tighten very well might interfere with throttle movement. Better to find it before you have the gas tank on.

Good luck with it, keep the photos coming.

Semper Fi

B D R
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post #28 of 40 Old Sep 26th, 2010, 1:46 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

With the help of Hallzee he was able to figure out that the cable adjustments were all we needed to get them free flowing... Got her started! Lord knows when the last time that was.. Rough, but seems to smooth out as she warms up... More to follow...

http://www.youtube.com/watch?v=Jkr-GJB_ewY

Youtube movie

Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
'05- K1200LT - Gretchen
R.I.P. - '00- K1200LTE- "Barbara" - Retired at 168K 9/2011
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post #29 of 40 Old Sep 26th, 2010, 1:59 pm
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by shoswell
The air box is the only thing with clamps? am I dense or ??? the cables stick even with the AB off..... Harrumph!

p.s.- Thanks Dick!
There are clamps under the TBs holding them to the stacks.

John
2009 K1300GT Red Rocket
2009 R1200GS (Gone)
2005 K1200LT Ocean Blue Blue Wizard 110 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

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post #30 of 40 Old Sep 26th, 2010, 2:54 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...





Cant seem to find these that I posted yesterday!!! Enjoy!
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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
'05- K1200LT - Gretchen
R.I.P. - '00- K1200LTE- "Barbara" - Retired at 168K 9/2011
MOA, IBA, EXR & RCB and TMI
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post #31 of 40 Old Sep 26th, 2010, 4:13 pm
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Re: Take a trip down the dark...dark rabbit hole...

Hoss,

After you helped me out with my wiring dilemma, I'm glad you got a break on changing your engine. Looks like you've got it about licked. I changed my throttle cables to the new style a couple of years ago and couldn't move the throttle at all. Turns out that I had routed the lower cable over the top of the fuel rail. Looks like your routing is correct, so I'm not much help here. But I'm reading every day or so and cheering you on from the other side of the country. The pictures really help too! Keep up the good work and hopefully, Barbara will be back to her old self before long.

Greg

"Loud lives save pipes"

00 K1200LT (Emil) 94,840 trouble free miles. Gone, but not forgotten
02 R1150RT (Artie) 109,000 miles. Favorite bike. With me to the end.
10 K1300GT (The Phantom) 10,110 miles. Like flying a T-38 on 2 wheels. Gone.
12 K1600GTL (Johnny 5) 3,500. A great compromise between the LT and GT

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post #32 of 40 Old Sep 26th, 2010, 5:24 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Good to see the cheers from the sidelines!

Just got her off the lift. Runs like a dream (so far) She has a high (pulsing) idle at this point. We are hoping that reseting the motronic will be the fix. It does not surge at speed only at idle! about 2K RPM...

Here are some parting shots...
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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
'05- K1200LT - Gretchen
R.I.P. - '00- K1200LTE- "Barbara" - Retired at 168K 9/2011
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post #33 of 40 Old Sep 26th, 2010, 7:20 pm
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by shoswell
Cant seem to find these that I posted yesterday!!! Enjoy!
Now that is how to put an LT on a diet!

That should make it easier to hold up at the stop lights!

2017 KLR650 "Mule"
2007 K1200LT "Starship Enterprise", VOICE II, Navigator V, Motorrad Communicator
1987 Kawasaki Voyager XII
1976 Kawasaki KH400
1973 Kawasaki 100 G5
1970 Rockford Chibi (the orange one)

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post #34 of 40 Old Sep 26th, 2010, 7:58 pm
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Re: Take a trip down the dark...dark rabbit hole...

Engine swap out in 3/4 of a weekend... We do good work, buddy!

Brian
CCR: 2008, Midway; 2011, Boise; 2012, Duluth; 2014, Chattanooga. MOA: Billings, 2015; SLC, 2017
CCR-R: 2018, Russellville
'13 K1600 GTL-P - "Eva"
Sold but "beloved" ride: K12 LT - "Pepe"
IBA #31242 (SSx2, BB, BBG)
MOA #136148

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post #35 of 40 Old Sep 26th, 2010, 9:47 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Well... Took a short ride up the hill and all (most) checks out good... A little odd getting a fresh motor... She pulls pretty hard!

Errors found thus far...
Cruise control is not working. Functioned before, but not now. Light comes on but the switch is dead for the most part...

Re-worked my aux lighting wires, One light cord is too short... Hella switch is constant on.. (wired at switch wrong)...

Surge issue is gone with the rest of the motronic.. Only issue as it pertains to the engine is a high idle...1500 vs 10-1200... We'll see if that works itself out....

For those that are following: to recap...
Complete teardown started at 0700 on Saturday...Ended on Sunday at 1500!


Your child IS supposed to help? right?



My sweet cheeks!!! Thanks for the support!



And a special shout to Webcrum.. Ed & Dovie for the loan of his Lift and jack!

Boy it is great to know you have good people to depend on in a pinch...


That means You UNCLEMARK are out of my will.. I mean really, picking Family over spending time with the beer, buds and bikes? You sir are PW!!!!!
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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
'05- K1200LT - Gretchen
R.I.P. - '00- K1200LTE- "Barbara" - Retired at 168K 9/2011
MOA, IBA, EXR & RCB and TMI

Last edited by shoswell; Sep 26th, 2010 at 9:58 pm.
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post #36 of 40 Old Sep 26th, 2010, 10:01 pm
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Re: Take a trip down the dark...dark rabbit hole...

Jeesh, all I did this weekend was cut the lawn...

Fantastic, thanks for bringing us along with you! The bike looks strange (and very unnatural) without a motor. Seems to me there is nothing that cannot be accomplished on this forum!

-Mike

Last edited by jello4; Sep 26th, 2010 at 10:27 pm.
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post #37 of 40 Old Sep 27th, 2010, 6:44 pm
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by shoswell
Well... Took a short ride up the hill and all (most) checks out good... A little odd getting a fresh motor... She pulls pretty hard!

Errors found thus far...
Cruise control is not working. Functioned before, but not now. Light comes on but the switch is dead for the most part...

Re-worked my aux lighting wires, One light cord is too short... Hella switch is constant on.. (wired at switch wrong)...

Surge issue is gone with the rest of the motronic.. Only issue as it pertains to the engine is a high idle...1500 vs 10-1200... We'll see if that works itself out....

For those that are following: to recap...
Complete teardown started at 0700 on Saturday...Ended on Sunday at 1500!

That is a pretty impressive weekend. I am hoping to complete by upcoming 24K maintenance in less than a week!

2017 KLR650 "Mule"
2007 K1200LT "Starship Enterprise", VOICE II, Navigator V, Motorrad Communicator
1987 Kawasaki Voyager XII
1976 Kawasaki KH400
1973 Kawasaki 100 G5
1970 Rockford Chibi (the orange one)

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post #38 of 40 Old Sep 27th, 2010, 8:43 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by Voyager
That is a pretty impressive weekend. I am hoping to complete by upcoming 24K maintenance in less than a week!

Thats next weekend... Supplies in route via Beemerboneyard!!

Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
'05- K1200LT - Gretchen
R.I.P. - '00- K1200LTE- "Barbara" - Retired at 168K 9/2011
MOA, IBA, EXR & RCB and TMI
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post #39 of 40 Old Sep 28th, 2010, 9:32 am
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Re: Take a trip down the dark...dark rabbit hole...

Quote:
Originally Posted by shoswell
That means You UNCLEMARK are out of my will.. I mean really, picking Family over spending time with the beer, buds and bikes? You sir are PW!!!!!
Sweet - does that mean I "get" the old engine??

Brian
CCR: 2008, Midway; 2011, Boise; 2012, Duluth; 2014, Chattanooga. MOA: Billings, 2015; SLC, 2017
CCR-R: 2018, Russellville
'13 K1600 GTL-P - "Eva"
Sold but "beloved" ride: K12 LT - "Pepe"
IBA #31242 (SSx2, BB, BBG)
MOA #136148

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post #40 of 40 Old Aug 9th, 2011, 11:33 pm Thread Starter
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Re: Take a trip down the dark...dark rabbit hole...

Update:

[QUOTE=shoswell]Errors found thus far...

Only issue as it pertains to the engine is a high idle...1500 vs 10-1200... We'll see if that works itself out....

The issue never "worked" itself out... As it turns out I did not replace the plugs for the vacuum. (to the canister)...

old engine with the plugs...


The new engine where I forgot to put them...
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Hoss
'Stupidity has a knack of getting its way.' --Albert Camus
'05- K1200LT - Gretchen
R.I.P. - '00- K1200LTE- "Barbara" - Retired at 168K 9/2011
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