Some of you may have read the shop manuals, either Clymer or BMW, on the Starter removal procedure. It goes....Remove rear drive, swingarm, tranny,raise the frame etc....etc....! At least 6-8 hours work for someone with all the special tools. I do not want to know what the dealer's quote would be on that one.
And Thanks to FlyingKiwi who got me interested in that one in the first place......I just hope that now he won't be too P.....Off from that surgery he had to do on his own bike.
I had some time waiting for parts for the clutch O-ring job, and decided to investigate a bit further. I can now remove and replace the starter in less than an hour. I cannot guarantee this will work on all the RS/GTs, there is zero clearance, so you may have to resort to a little grinding with the Dremel, but nothing serious. But I got mine in and out 5-6 times just to make sure of the procedure, it works and now I know that I can remove my starter on the side of the road if need be.
-Disconnect the battery
-Remove the coils.
-Remove the seat rail/fuse box holder and push the wiring and fuses out of the way.
-Disconnect the Alternator.
-Disconnect the Starter.
-Remove the small ground on the cross-frame
-Remove the 2 starter mounting bolts and ground wires.That one is a little tricky, you will need a long ball-end Allen wrench to reach the inside bolt.
Pull the starter back by about 1" and turn it counterclockwise until the mounts are at about 120 Degrees from their original position.Like this:
Now move the back of the starter upward while keeping the front part down, that is to clear the boss in the casing.This takes a little wiggling to clear the obstructions such as the alternator post.The starter has to go as far up as possible and should look like this when you are done.
Now work it backward, you'll notice the ground wire is still on the cross- frame, it has to come out, zero clearance.
As you are doing that, work the front of the starter to this position.
This is where it gets tricky and where you may have to relieve the corner of the casing with a file or Dremel tool. I did not have to, but like I said, zero clearance....!
Pull the gear end of the starter away from the casing and slide the starter forward.....Et voila, you should have a BMW starter in your left hand to do as you please with.
Reassembly is exactly the reverse,but look carefully at the second pic, it has to go back exactly the same way.
Push it back and up from the front until it is back at the point where the gear meets the casing, push in in there and carefully work it back in place holding the front of the starter slightly up. You have to make sure the gear clears the boss on the case, and a little lube on the O-ring helps. Here is a pic of the boss you have to clear:
I could go a little farther in this procedure by saying that you could free a sticky starter clutch once the starter is removed, but I haven't tried that. But from what I can see, you could rig a flexible hose on a can of carburator cleaner and spray behind the starter gear into the starter clutch, possibly cleaning/freeing it that way.
But my question begs here....Did anyone have to pay "a few" hours shop rate at a dealer to have their starter replaced or serviced????