R1200GS: 60,000 mile service [page 2]

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Sunday, Jan 23, 2011 [59966 miles]

Foam air filter

Foam air filter

Foam air filter
ISO 50   f/2.8   1/60   0 ev   7.3mm
Freshly oiled

Freshly oiled

Freshly oiled
ISO 50   f/3.5   1/60   0 ev   12.6mm

Decisions, decisions… where to start. Front shock? Brakes? Valves? How about the air filter. I’m switching from stock paper to a Uni oiled foam filter. I sprayed a lot of oil onto the foam and worked it in with my fingers. It’s sitting in a plastic bag letting any excess oil drip out.

Unclip snorkel

Unclip snorkel

Unclip snorkel
ISO 50   f/2.8   1/60   0 ev   7.3mm
Used filter

Used filter

Used filter
ISO 50   f/2.8   1/60   0 ev   7.3mm
Clean air-box

Clean air-box

Clean air-box
ISO 50   f/3.2   1/60   0 ev   8.5mm
Foam filter installed

Foam filter installed

Foam filter installed
ISO 50   f/2.8   1/60   0 ev   7.3mm

I used air to blow the crap around the air-box away and wiped things down with a damp rag before unclipping and removing the snorkel. The inside of the air-box looked OK. I installed the foam filter, but held off on the snorkel as it might be in my way for what comes next.

Support for front

Support for front

Support for front
f/4.0   1/100   0 ev   7.3mm
Shock top mount

Shock top mount

Shock top mount
ISO 50   f/2.8   1/60   0 ev   7.3mm
I cheated

I cheated

I cheated
ISO 50   f/2.8   1/60   0 ev   7.3mm

Shock removal time. I put a scissor jack under the engine case (it just fit between the rubber bash plate mounts) and jacked it up enough to touch the case. I cheated with the top shock mount, using an air impact to break it free. It’s easier than trying to keep the shock from moving.

Top shock hardware

Top shock hardware

Top shock hardware
ISO 69   f/3.5   1/60   0 ev   21.7mm
Lower shock hardware

Lower shock hardware

Lower shock hardware
ISO 50   f/2.8   1/60   0 ev   7.3mm
Bottom free

Bottom free

Bottom free
ISO 50   f/2.8   1/60   0 ev   7.3mm
That's better

That’s better

That’s better
f/2.8   1/60   0 ev   7.3mm

I heated the lower mounting screw with a Mapp gas torch until about 300F then used a ratchet with a T-50 head to remove the screw. With the shock pulled close to the engine it couldn’t drop down quite enough for removal. I used the scissor jack to raise the front until the top of the shock came free. Careful with brake line tension when raising the front.

Needs rebuild

Needs rebuild

Needs rebuild
f/2.8   1/60   0 ev   7.3mm
Rebuilt replacement

Rebuilt replacement

Rebuilt replacement
ISO 50   f/2.8   1/60   0 ev   7.3mm
Cleaning hardware

Cleaning hardware

Cleaning hardware
ISO 50   f/3.2   1/60   0 ev   7.3mm

Before starting to mount the replacement shock I cleaned up the bottom mounting screw and the threads in the A-arm. It took a few tries before the screw would thread easily by hand.

Thread locker and anti-seize

Thread locker and anti-seize

Thread locker and anti-seize
ISO 50   f/2.8   1/60   0 ev   7.3mm
Bottom torqued

Bottom torqued

Bottom torqued
ISO 50   f/4.0   1/80   0 ev   7.3mm
Top torqued

Top torqued

Top torqued
ISO 50   f/2.8   1/60   0 ev   7.3mm
Tools

Tools

Tools
ISO 50   f/2.8   1/60   0 ev   7.3mm

I should use a new bottom screw with BMW’s encapsulated thread locker. The book also calls for anti-seize. Instead I noted where the screw threaded into the A arm and applied thread locker to that portion and anti-seize to the rest. I also used thread locker on the top nut. I used the shock pre-load adjusting wrench to keep the shock from turning while torquing the top nut to spec.

Clutch cap tool

Clutch cap tool

Clutch cap tool
ISO 50   f/3.5   1/60   0 ev   14.9mm
Not too full

Not too full

Not too full
ISO 50   f/3.5   1/60   0 ev   17.3mm
Put bellows back

Put bellows back

Put bellows back
ISO 50   f/3.5   1/60   0 ev   17.3mm
Clutch OK

Clutch OK

Clutch OK
ISO 50   f/3.5   1/60   0 ev   17.3mm

As the clutch wears the clutch fluid rises. I removed the cap after cleaning using my super special cap removal tool (a bent hanger). Level is fine. No contamination noted. That’s all for clutch maintenance.

Rear brake control

Rear brake control

Rear brake control
ISO 50   f/3.5   1/60   0 ev   7.3mm
Capture old fluid

Capture old fluid

Capture old fluid
ISO 50   f/4.0   1/160   0 ev   8.5mm
rear reservoir

rear reservoir

rear reservoir
ISO 50   f/4.0   1/160   0 ev   7.3mm
empty

empty

empty
ISO 50   f/4.0   1/320   0 ev   7.3mm
Sealed bottle

Sealed bottle

Sealed bottle
ISO 50   f/4.0   1/125   0 ev   7.3mm
Out goes the old

Out goes the old

Out goes the old
ISO 50   f/2.8   1/60   0 ev   7.3mm

For no particular reason I started the brake bleed at the rear control circuit. I use a MotionPro one-way valve instead of speed bleeders. A syringe dedicated to brake fluid helps suck fluid out of the master cylinder. The job is easy. Hardest part is not spilling the bit of fluid left in the tube when pulling it off the bleeder.

Front control circuit

Front control circuit

Front control circuit
ISO 50   f/4.0   1/160   0 ev   17.3mm
Front reservoir

Front reservoir

Front reservoir
ISO 50   f/4.0   1/400   0 ev   10.8mm
Control circuits bled

Control circuits bled

Control circuits bled
ISO 50   f/3.2   1/60   0 ev   10.8mm

The front reservoir had some black specks at the bottom. I wiped it down with a paper towel after drawing out the old fluid with the syringe. Also, I remove the ABS electrical connector to get easier access to the bleed valve. When done I topped off the reservoir, cleaned around the bleed valves with a damp rag, and finished by re-installing the bleed valve caps.

Cleaning

Cleaning

Cleaning
ISO 50   f/4.0   1/80   0 ev   7.3mm
Front cover

Front cover

Front cover
ISO 50   f/3.5   1/60   0 ev   7.3mm
Engine bottom

Engine bottom

Engine bottom
f/3.5   1/60   0 ev   7.3mm
Snorkel back in place

Snorkel back in place

Snorkel back in place
ISO 50   f/4.0   1/125   0 ev   8.5mm

I’m going to delay doing the wheel circuits until tomorrow. At this time of year the sun pours into the garage in the afternoon, making it uncomfortable to work. I did spend a bit of time cleaning up the engine case and re-installing the front cover. I put the snorkel back, too.

 

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