I completed all my annual service in early March on my 05 LT and also flushed the EHCS w/o disassembly. I have now serviced this unit in 2010, 2011, and 2013. The first flush in 2010 actually included disassembly and replacement of seals/o-rings so that really wasn't a flush per se. After inspecting the fluid in 2010, 2011, and 2013, I will likely flush/drain/replace fluid five or six times when the unit is removed annually. This is also a good time to clean/lubricate the center stand and side stand fulcrum locations.
What was not covered in depth in the original EHCS article by Joe Gottberg is cleaning/lubrication and reassembly of the DC electric motor. The motor is a simple design with two spring-loaded carbon brushes in contact with the rotor armature commutator. Through normal wear, brush dust accumulates and the armature ends should also be re-lubricated.
The brushes, electric motor, and pump individually are not available as parts...the entire pump/electric motor unit must be purchased. The pump is also not available from Marzocchi since there is a proprietory agreement b/w BMW/Marzocchi whereby owners must purchase through BMW.
Exercise care when retracting the two spring-loaded brushes to their outer travel limits immediately before inserting the armature. An extra set of hands comes in handy for this operation. You do not want to chip the brushes when inserting the armature.
For complete disassembly and replacement of seals/o-rings, they are still available from Allied Metric Seals and Fasteners Inc. (973)383-24887.
They sell ea kit for $25. When I purchased a spare electric motor and two sets of brushes in 2010 from a separate vendor, the motor was $50 and replacement brushes were $9/pr
. I believe this is is the same motor used as a Honda 80cc starter. Another rider originally found this replacement about in 2008. The brushes on this motor do not have the same design as the OEM motor on the EHCS.
I recommend servicing the motor every four years and multiple flushing the EHCS hydraulic jack oil until it 'cleans up' each time the unit is removed; two years maximum b/w services. If one doesn't wish to flush multiple times, complete disassembly of the pump with seals/o-rings replacement is an option. Exercise CAUTION when installing the four rods which compress the cylinder to the top. The top is made of inexpensive pot metal and cannot tolerate much torque. I cleaned the top, roughed the outside with a Dremel bit and coated the top with about 1/4" layer of J-B Weld.
Replacement of the EHCS from South Sound BMW is currently $1400 w/o labor...this pump/motor unit can be purchased out-of-state for about $300 less. Hope this has been helpful for LT owners of 05+ models. Please see the original Joe Gottberg article for servicing details.