Originally Posted by Bumlinger
It sure does sound like the CCT, especially when the clutch is performing as normal. Makes me think it's not the clutch. It's amazing how much noise the tensioner (or non-performance of the tensioner) can make. I probably shouldn't have ridden it 50 miles like that. I suppose the Jump Guard must have done it job! I ordered the new CCT assembly from my local dealer, should be in my hands in a week. I did not look to see what style is in there currently. Old or new style, it isn't working for me. I also bought a new clutch cover gasket and a set of new bolts. I will probably take a look inside to see what I can see.
Any tips or tricks on installing the new CCT? Does it need to be "primed" with oil prior to installation? If I take the clutch cover off, is there anything I should be aware of or looking for?
You will need to pull the plastic K1200GT side panel off to replace the reservoir. If you have never done it before, take your time. Look for the hidden screw behind the top rubber flap in the front. There is also a plastic plunger that fits into a rubber grommet that requires a straight pull to get it off. When replacing the panel, there are lots of little tabs that fit into little slots - take your time. A great tip that I learned from a friend is to take a photo of your side panel (or get one from the Internet. Tape the photo to a box lid, like the one that comes with a box of copy machine paper. As you remove the screws, punch them through the photo at the same location, to help you remember where they go. There are many different screw lengths, so it is easy to get them confused. I still have the same pair of box lids that I used 8 years ago.
Here are the instructions from the BMW RepROM for installing a new cam chain tensioner with reservoir are:
* Install new seals (the image shows small and large rings above the piston, below the reservoir).
* Install timing chain tensioner (the piston).
* Place oil reservoir in position with the recess towards the inside; make sure that the clutch pressure cannot chafe against the oil reservoir. (The image shows a small "notch" behind one of the screw holes - that's the "recess".)
* Hold oil reservoir against the force of the pressure and install OILED washers with screws. (The image shows washers between the screw heads and the top of the screw holes on the reservoir.)
M6 x 16
Initial torque, 9 Nm
Loosen, 90 degrees
Final torque, 9 Nm
There are no comments about pre-filling the reservoir. I assume it is not necessary. Besides, it would leak out and make a mess when you flip it over to screw it down.
I do not understand why you purchased the BMW brand tensioner, nor the gasket and screws. I would have spent the money on an APE tensioner and forgone the BMW one.
Before I continue, I need to warn you that I am NOT an expert. I have book knowledge, but not that much experience. In addition, I do not know how many miles are on your K1200GT. I hope someone with real-world experience can offer more advice.
If you open up the cover, then I would look at:
* Cam chain jump guard: Is it in good condition. It is made of plastic and could have been damaged.
* Other damage inside or metal flakes?
* Cam chain wear - is it damaged, stretched, or ready for replacement?
* Timing (cam) chain rails - do they look okay?
Note: Replacing the timing (cam) chain or bottom rail is a very big job. You'll have to remove the radiator and valve cover, to get at the top of the engine. That's something you might save for when you do a valve clearance check.
Get a RepROM DVD from your BMW dealer. You will need a Windows computer (or a Windows virtual machine on your Mac). Buy a genuine, latest RepROM DVD from your dealer; PLEASE do not feed those @#[email protected]
on the Internet who sell bootleg copies of old versions.