2005 k1200 gt engine sudden failure - K-Bikes.com - Excellence in Motion
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post #1 of 14 (permalink) Old Sep 3rd, 2019, 4:13 pm Thread Starter
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2005 k1200 gt engine sudden failure

2005 K1200 gt with 67k, riding at 70 / 80 I smell of rubber burning as if of tires, without any warning light engine shakes left to right and dies under the shade of a tree, The recent service history includes a new fuel pump and filter, and a fresh air filter.
I would like to chase down what in the motorcycle world might have happened and fix it myself, any idea or theory much appreciated.
Thank
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post #2 of 14 (permalink) Old Sep 4th, 2019, 8:30 pm
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More facts are needed. Coolant level or out? Oil level or out? Or could it be just an electrical failure and you were smelling burnt wiring. What will the bike do now? Other visible clues to failure? Rod sticking out of case?
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post #3 of 14 (permalink) Old Sep 4th, 2019, 11:27 pm
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2005 K1200GT? Probably not a classic brick engined BMW K1200RS/GT.

Question there maybe with details:

https://www.k-bikes.com/forums/43-k12-1300gt-next-gen/

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post #4 of 14 (permalink) Old Sep 9th, 2019, 4:38 pm Thread Starter
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here where the gremlins escaped! Never seen this before in my motorcycling career.
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post #5 of 14 (permalink) Old Sep 9th, 2019, 5:18 pm
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Quote:
Originally Posted by dominik66 View Post
2005 K1200 gt with 67k, riding at 70 / 80 I smell of rubber burning as if of tires, without any warning light engine shakes left to right and dies under the shade of a tree, The recent service history includes a new fuel pump and filter, and a fresh air filter.
I would like to chase down what in the motorcycle world might have happened and fix it myself, any idea or theory much appreciated.
Thank
Quote:
Originally Posted by dominik66 View Post
here where the gremlins escaped! Never seen this before in my motorcycling career.
WHAT WAS YOUR OIL LEVEL at time of failure ?? Measured on center stand only on level surface.

I suspect a broken connecting-rod on cylinder number 1 (front cylinder). You need to remove this crankcase cover to confirm. This has happened mainly on the early engines of K1200RS (1997 and a few early 1998 production). See attached photo of one of these cases.

Somewhere mid 1998, BMW changed the connecting-rods design and the bolts attaching the bottom half of the rods - from then on there has been VERY FEW of these failures. Keep in mind the K1200GT of 2003-2005 use the same engine as a K1200RS of the same era.

During last 15 years on 3 different K1200RS forums, I have seen many such failure on the early engines (1997-1998), but only 1 case on later models like yours. If this is your problem, then you would be the 2nd case (that I am aware) for later engines using the new connecting rods design.

IMPORTANT: A lack of lubrication (low oil level) OR lack of oil pressure (defective oil pump , bad install of oil filter , loose oil filter) can cause exactly the same result as above. Cylinder 1 connecting rod oil flow is such that it tends to fail before the other in such condition.
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~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
John (Montreal, CANADA)
K1200RS (2002 IceBlue/Red - 96,000 miles)
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
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post #6 of 14 (permalink) Old Sep 9th, 2019, 10:03 pm Thread Starter
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This seems indeed be the case. Oil level was just a tad below center mark, tomorrow will open her up and check oil filter and pull crankcase cover off to assess repairing or scrapping for parts.

Needless to say I'm stupified!
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post #7 of 14 (permalink) Old Sep 10th, 2019, 8:15 am
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Originally Posted by dominik66 View Post
This seems indeed be the case. Oil level was just a tad below center mark, tomorrow will open her up and check oil filter and pull crankcase cover off to assess repairing or scrapping for parts.

Needless to say I'm stupified!
Oil level "just a tad below center mark" is NOT a problem.

Was there an oil filter change just before this happens ? If so, check for all these items:
- oil filter used (brand / number)
- oil filter being loose
- usage of 2 rubber gasket on top of oil filter. I have seen cases where the old rubber gasket from old filter being removed stayed stuck on top and the new one was accidentely installed over this one.

I AM VERY CURIOUS to see photos of what you find behind the crankcase cover...

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
John (Montreal, CANADA)
K1200RS (2002 IceBlue/Red - 96,000 miles)
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
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post #8 of 14 (permalink) Old Sep 10th, 2019, 6:57 pm Thread Starter
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full scale survey of a blown brick engine

John, you seem to know this subject well and I am grateful of your knowledge and help.
Indeed oil filter was replaced with a fram PH6063 less than 2 months ago, just hand tightening as I always did, but without two gaskets as you mentioned. Oil Level tells a quarter of oil is missing, this in less than two months use.

Apologies for orientation of pictures, left side of bearing in first picture corresponds to top of engine.

Connecting rod of piston #1 disintegrated, bearing destroyed, crankshaft a mess, some engine case shavings.

Piston #2 appears dry compared to #3, #4. probably next to immediate failure.

Decisions, Decisions, Decisions!
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Last edited by dominik66; Sep 10th, 2019 at 8:36 pm. Reason: add picture
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post #9 of 14 (permalink) Old Sep 10th, 2019, 8:37 pm
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I am not a Fram fan.Somethin strange about them is that the threads are 3/4-16 ? BMW threads are 20mm.

FRAM Motorcycle Full-Flow Spin-on Oil Filter PH6063 | FRAM

I'd cut it open for an inspection.Other than that I have heard of the odd blown post 98 engine.But not many.Still keeping an eye on mine at now +285000 kms.Using a little oil as in 1L/10,000kms but oil pressure has been steady at over 70psi for all them years watching my proper oil pressure gauge.

Idiot light spec is 5-8psi coming ON which is too late for most engines.

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post #10 of 14 (permalink) Old Sep 10th, 2019, 10:13 pm Thread Starter
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no engine light on mine whatsoever, just dead. Idiot myself too for not checking oil level on regular basis; you just can't trust instrumentation panel to save your bacon.
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