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Discussion Starter #1
It's a long story but the bottom line is I threw the rod cap on cylinder one over Labor Day weekend. The rod cap got pushed through the top of the block. It appears I broke a rod cap bolt. Found the bolt with the nut still on it in the case upon disassembly. Only notice I had that something was going wrong was a little knock that went away when I added more oil. Came upon some slower traffic, downshifted and BAM! Luckily I had the clutch pulled in so I just coasted over to the edge of the road.

After being quoted $12,500 for a new motor by the local BMW dealer, I thought I would just part it out. That's where ErineA on this website comes in. Ernie had me over a few years ago to teach me how to do the 12K maintenance including the valve check. I purchased a lift and modified it to lift the Dragon (my trike). I've done all my own maintenance ever since. It is yet to be determined if I did or did not do something that lead to the failure. I was whining to him about my predicament. He felt we could re-build her for a third of that price. So, I took my lift to Ernies, and we started disassembly while I looked for a used engine. Found one from LTPARTS.COM with about 40K on her. Mine had 58K, 24K when she was triked. Ordered a butt load of parts from Denver BMW (they gave me the best discount and free shipping). It sure is nice to have mechanically skilled friends.

About this time, after completely removing ALL of the body parts, my wife asked me if I was going to have the Dragon painted while she was all in pieces. I said, "Sure, what color would you like?" We settled on deep red metallic with gold metallic trim (Think Ironman colors) The Dragon was an 05 in light yellow metallic. I also removed the wheels, fork tubes, ABS wheel ring on the front, engine covers, foot brake pedal and Ztechnic arm rest supports and took them to be powder coated to match the trim color. There are 21 trim pieces to be painted and 23 body panels to be painted. Got an $1800 quote for this work from a friend who manages a major collision center in Bend, OR. My wife also has a Viking Diamond Embroidery Machine and we have modified a few designs to have Dragons put on the back rests and knee pads. A local auto upolsterer is cutting out the material, then we will put on the designs and they will re-assemble.

Ernie and I continue to work on the bike but slowly, as Ernie also works for UPS and this is the busy time of the year for them. Existing or planned work includes: new valve guide seals,polishing the ports, cleaning & re-assembly of the existing head; rebuild of the oil/water pump; new clutch & pressure plate; drilling the weep hole; new fork seals; new front wheel bearings; replace all of the engine bearings in the used motor; new pistons, rods & rings as needed; replace the rear shocks; replace the fuel transfer pump for the auxiliary tank; and add LED lighting for accents. I'm sure I forgot a few things but basically, she'll be rebuilt for the ground up. We have been taking extensive pictures of the tear down & re-assembly. I'm sure Ernie will post more. Look for a thread called "Inside your engine" in the main LT forum category. We will post pictures upon completion of our project. The Dragon should roar back to life by late March or early April.

Wish us luck.
 

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Randi
looks like you have the situation well in hand.
Looking forward to updates........
 

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Good Luck on your reserrection.

I just went through a similar situation on my trike. The Transmission went bad early in the summer. By the end of the summer, I got the trike back. It only cost $6,500. I can understand the heavy cost when you consider that it required complete disassembly (Trike assembly, engine assembly, etc. The mechanic commented that he never wanted to work on a trike again. One month later the starter relay and the master brake cylinder went bad. That killed my trip to Mexico. But fortunately he worked on it since it did not envolve the trike section.

My days of working on a bike are long gone (Too Old). Where are you and your friend located? Would he be willing to work on a trike in the future? I am located in Ranger Texas. Near Abilene.

Thanks,

Richard Cohen
Ranger, TX
2002 K1200LT Trike
1979 R65
 

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Randi,


Holy moly...that is a lot of wrenching to do on a tricycle. I hope it all works out well. You are smart to employ Ernie's expert skills...he really knows the LT as well or better than any of the experts out there.
 

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Hey, good luck, Randy!! My 2000 LT trike has a minor oil leak, and being the quality control person I am, it is driving me nuts! When it quits raining, I'll go looking for a wrench who will work on a trike. Las Vegas BMW does not want to do so.

At one time, NECE said to bring it back, they'll work on it! A thought! :)

Jerry
 

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Discussion Starter #7
Richco, I'm in Salem Oregon and Ernie lives just 40 miles away in the Portland area. Thanks to all who have commented. I know it is a huge undertaking but without Ernie's help, I wouldn't even try. She'll be quite the showpiece when Ernie, a host of others, and I get done. We'll post pictures soon. Thanks for everyones encouragement. I plan on attending CCR this year. I'll be moving back to Bend, Oregon in June. That puts me just 4 hours from Boise. Hope to see alot of you guys at CCR.
 

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Re: Re-building (your) Dragon

I put the rest of your front end together today Randi. It looks real sharp with the new powdercoat. Powdercoating has left us with the challenge of chassing threads with taps prior to any install I'm afraid. The coaters did not plug all holes and that lets a whole host of media into the threads. The axle holes in the sliders needed some attention for the axle to slide in and out smoothly as well.

Enjoy!

 

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Hey, Randi, what's the status now? Pics?

Be safe.

Jerry
 

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scubajgp said:
Hey, Randi, what's the status now? Pics?

Be safe.

Jerry
I'm not Randi but can shed some light on the progress. The used engine is in the process of being rebuilt. I will be assembling the engine this weekend now that the new pistons came from Germany this past week. Vacations over and now its time to get her back on the road. More pictures of the assembly will be posted in the coming two weeks as she retakes her old (but much different) form.
 

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Discussion Starter #11
Thanks Ernie for reporting on the motor. I got most of the body pieces (Deep Red Candy Metallic) back from the painter. Now they are working on the trim pieces (Gold). I will start re=assembling all the hardware on the body pieces. Pictures are coming soon. Mid April the beast will be back.
 

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Discussion Starter #12
OK. Here are a few pics of the red body parts. They are covered in dust but I think you'll get the the idea.
 

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Thanks to you both, Ernie and Randi. Ernie, for you info, I had an LT converted to a Hannigan in Colorado just after Randi. We, Randi and I, have communicated in the past, and I appreciate your input! I remember that he had a broken axle, very unusual!

Randi, that color is amazing, like no other LT!!

Be safe, both of you!

Jerry
 

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Ernie, I see you are in Milwaukie! My family lived in Metzger when I was born, as in 1936! Metzger will never be the same! Chuckle!!

If you are not familiar with Metzger, it is now between that huge shopping center (Washington Square) and Multnomah. It was just a sleepy country hollow!

Anyway, at the time, we thought that Milwaukie was a metropolis!!!! chuckle
 

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scubajgp said:
Ernie, I see you are in Milwaukie! My family lived in Metzger when I was born, as in 1936! Metzger will never be the same! Chuckle!!

If you are not familiar with Metzger, it is now between that huge shopping center (Washington Square) and Multnomah. It was just a sleepy country hollow!

Anyway, at the time, we thought that Milwaukie was a metropolis!!!! chuckle
I know Metzger area well. You are right it is smack-dab in the middle of the Beaverton/Hillsdale/Multnomah suburbs. Milwaukie, on the other hand, is still the metropolis it once was and will never be.
;)
 

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Re: Re-building Randi's Dragon

Today I started to assemble the engine on Randi's tike. The parts are all in and vacation is over so the work will now commence.

I started organizing cleaning and storing parts over the past couple months. Randi had to order the piston kits and a main shaft that came from Germany. Today I set up a clean environment to do the assembly work (my bench). I then followed the assembly process that is mapped out in the CD version BMW manual. It pretty much is a reverse of how I took it apart but with a few small changes. I like to follow the procedure rather than try to remember what I did 8 weeks ago anyway. ;)

Today I finished rebuilding the water/oil pump and bagged it for a later install. I then assembled the new main shaft and installed it into the crankcase and sandwiched it in with the sump housing. Next I assembled the the oil pick up tube and sump cover. That is all for tonight. Tomorrow the assembly calls for the rear cover and clutch assy. It should be fun!

I've posted more pictures in my gallery. For some reason the thumbnails are not working but you can read the captions for what work is being done. I hope you enjoy the adventure as much as I do.
 

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Re: Re-building (Randi's) Dragon (It lives!)

Yesterday was a milestone day for the Dragon project. Randi's tike (The Golden Dragon) broke a connecting rod last August and it has been a long winter of rebuilding the trike to Randi's custom specs. The engine was totaled and the new (used) engine was in need of a fairly major rebuild on its own.

Randi asked me to be a part of bringing his Dragon back to life. We started on the project in September and it is starting to come to a close. Yesterday I fired up the new engine for the first time. It sounded sweet to hear the engine fire off and settle into a smooth idle at just under 1k. I hooked up the GS911 and all functions are nominal. It is time to bolt up the rear section and put together the bodywork this weekend.

Here are a few pictures of the Dragon as she sits now:



Just before hitting the start button I'm putting the finishing touches on the engine and cooling system. Randi brought over some body pieces and we put the front fender on to check out the color. Outstanding!



I had to move my overhead support to be able to roll the rear section into place. Man there are a lot of bolts holding a Hannigan Trike together!

More pictures as the Dragon comes together. Randi has some surprises ahead for upholstery design that may be as exciting as his paint work. I'll check back and post more as we close this long chapter and get Randi back on the road.
 

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Re: Re-building (Randi's) Dragon (It lives!)

Boy oh boy, Ernie. Next time you open your shop closet, you oughta find it chock full of *atta boys*!!! Great job. Can't wait to see it all finished and on the road. Bet Randi can't wait either. Bet you can't wait either. Bet lotsa of your work oughta be in the HoW pages somewhere!!! Take care, Ernie.
 

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Re: Re-building (Randi's) Dragon (It lives!)

Dick said:
Boy oh boy, Ernie. Next time you open your shop closet, you oughta find it chock full of *atta boys*!!! Great job. Can't wait to see it all finished and on the road. Bet Randi can't wait either. Bet you can't wait either. Bet lotsa of your work oughta be in the HoW pages somewhere!!! Take care, Ernie.
Thanks Dick! You always brighten my day here in the Pacific NorthWet. When we are finished with the Dragon I will take the time to put together some write-ups that might be helpful to anyone wanting to tackle a big project. To tackle a big job like this takes a lot of patience, and Randi has enough of both of us!
:bmw:
 

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Re: Re-building Randi's Dragon

The process of rebuilding the Dragon has been slow, but speed does not always win the race. Randi has been patient with the process of me working on the Dragon in my free time when I was working my regular job and now as I start a new PT career mixed with retirement. The new engine installed and running was a big thing for us (understated). For the last week I would find myself going out to the shop and just starting it up to listen to her run. It is an exhilarating feeling to hear an engine start up for the first time after a total engine overhaul.

Now the hard part of putting all of the little pieces back together. Organization of parts is key to remembering where things go when this process is initiated. This I have to admit was something I did not do well. When it came to the engine and other components I did a much better job of organizing the pieces to simplify the reassembly process. Now I'm hunting for nuts, bolts and screws! Note to self: Organize NEXT time!

So we are now putting the tupperware back on and Randi has been a great help in the process. Here are a few shots of the Dragon in the past two days:



Randi helping to assemble the Stingray



The nose and front fender are installed



The dash and Stingray look real good!



Randi lookin' like a proud papa!

The Dragon lives and is almost ready for its first ride.
 
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