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Discussion Starter · #21 ·
When was the last time you cleaned or checked the ventilation for the crankcase?

Hose had a 1mm hole left to be 100% clogged. Oiltrap was filled and when i poked around in it pure water just ran out then the crud, pic show about 1/3 of the crud from the hose.Did not intend to take the airbox off but decided to do it so i could clean then top of the engine before opening up the valvecover for inspection. Glad i did, if this has clogged upp completely, seals would have blown with hard or expensive fixes of oil leaks.
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Discussion Starter · #22 · (Edited)
Cleaning, getting a lot of sand and pebbles off the top of the engine. Also cleaning the rubber between airbox and throttlebodies, putting some siliconegrease in them to slow down aging. Also cleaning out the oilresidue in the top of the throttlebodies.
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Discussion Starter · #23 ·
Fitted new springs in the basket, a trial, used 2 yellow hard and 2 slightly softer red springs.
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The bolts in backinplate are m10x1 and used orapi 298 threadlocker, can be undone to change springs if needed, torqued the to 30nm. Removed the paint on them beffore fitting. To the left in pic before paint removal, middle after, to the right the 4 oe springs.
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Now just to cure for 24 hours before fitting lamellarpack and in the bike.
 

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Discussion Starter · #24 ·
Clutch is back in the bike after soaking in oil for 24 hours. Began changing timing chain and tensioner and slide rail. Went just fine up until reinstall, the screwholes and guidepin doesent line up, timing is off.
Tried skipping a tooth forward but the timing is equally off in that direction as well. Crank need to be turned, should i fit the gear as in the pic and rotate the engine forward 8normal direction) until it lines up and that will be fine. Or move the gear 1 tooth forward and back the crank until it lines up.

Lost here, manual said nothing about this.......
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Hey Mattias. Four hundred four who rebuilds the bmw clutches said do not shim the springs. They will bind. He gets new springs made up so he may provide you with a set. His email is
[email protected]
He rebuilt my clutch and did a first class job
 

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Discussion Starter · #26 ·
Hey Mattias. Four hundred four who rebuilds the bmw clutches said do not shim the springs. They will bind. He gets new springs made up so he may provide you with a set. His email is
[email protected]
He rebuilt my clutch and did a first class job
Have asked but got no response. Depends on how you shim, pressing things in until it all is solid i guess it will bind. But with the caps i have in mind a small play can be set as the shim is on each end and will be machined to size.

But i have fitted other springs for a trial, right now the trouble is the timing chain and sprocket for it as seen in the post before yours.
 

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Discussion Starter · #27 ·
Changing brake rotors on the front.
Used a gas torch to carefully heat the post's and bolts, then remove the screw's.
Threads need cleaning and since it is aluminium i like to use a 3 tap set, pre, middle and finish, lessens the risk of damaging the threads or crossthreading.
Cleaned the debree from tapping out with brakecleaner and compressed air.
Screw's were also cleaned, then refitted the new rotors with new bobbins but reused the old screw's, just applied new threadlock on them.
Then just to refit the new parts and torque down to 19nm.
Pad's will be replaced as well, brembo red going in.
Old part's will be saved as spare's, disc's are fine and pad's only have 1 season on them.
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Discussion Starter · #28 ·
Had trouble finding a usable set of piston spreaders that can press all 4 pistons in the caliper at once and also do it with the wheel on the bike and be used to press against when bleeding.
So i built some fast and easy spreaders myself. It's not pretty but they work and that is all that matters.
70x70x8mm steel plates, a m8 screw, an m6 locknut and 2 washers.
One plate drilled and tapped m8, the other drilled 6mm hole. Screw had the tip turned down and threaded m6x1. Put it together.
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Discussion Starter · #29 ·
Radiator fitted again after cleaning, just refill left. also started putting the aux lights back on the bike, will build a new wiringsystem for it and use a new controller for dimming. This time i will add an on/off switch, either a digital or a simple pressbutton, not decided yet. Lights on the forks are dimmed to about 10% power along with dipped beam, applying highs put them on 100% and also lights up the 15w in front of the oilcooler.
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Discussion Starter · #30 ·
Made my own quick disconnect for the fuelline. Aluminium and can be taken apart for replacing o-rings if needed.

Also made the first startup today, sounded horrible the first few secinds as the tensioner was empty. But once filled it was quieter than ever, no rattle coming throttle. And while idling it was quiet and no change in sound with clutch pressed or not. Springs made a difference.
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Work work work, oh well.
Got a genuine Bmw HP carbon front fender and a set of HP rearsets for just €160, that is $195 for the yankee's. 😃
I take offense to that. Not all Americans are Yankees. JK. I’m enjoying this thread immensely.
 
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Discussion Starter · #32 ·
First drive for the season.

Had i known what the clutch would be like with new frictions and springs, i would have done it in 2017 when i bought the bike!!!!!

I am in love all over again, it is like a new bike!

So so so so sooooooo smooth! Low rev city driving on/off jerking is totally gone!!😯🤯😃

Finding neautral now is amazing, it is a distinct position, it shifts so nice. The bang when engaging first is totally gone when engine cold, when hot it comes back, but is reduced to almost nothing compared to before, if before it was like using a sledgehammer now it is like using a carpenters hammer.
Backlash while decelerating is gone, even going downhill just letting go of the throttle and downshifting using enginebrake. Drivetrain is silent, the springs of correct length can now do what they are supposed to do.
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Discussion Starter · #35 · (Edited)
Been out on another drive, did about 40km of twisty roads and the clutchjob is a huge improvement with the drivetrain slack gone, so much easier in the twist and turns with the sharper power delivery.

Also noticed that the area of the clutch were it can be feathered is much narrower, but that is most likely down the stack being thicker as it is new, and because of it being new also it "bites harder" will take a little getting used to thats all.
 

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I have to agree with Fried_Chicken. I'm southern born and bred and would never like being called a yankee. My family has been here since the early 1700s. And yes, my great great grandfather fought in the civil war for the south. And before a yankee comments, I'm college educated, I'm an engineer, and my house is not built on the side of a hill, although I do live near the mountains.:)
 

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Discussion Starter · #37 ·
On this side of the pond all citizens of the USA are yankee's. cant change that, just live with it, like you call all of us on this side europeans. Were not, but we just let it slide.
 

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Ok, I want to install these springs. My clutch is a rattly joke.

My understanding is you need to tap out and make new threads for larger bolts?
What parts do I need here?

Very nice work Mattias
 

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Discussion Starter · #40 ·
Ok, I want to install these springs. My clutch is a rattly joke.

My understanding is you need to tap out and make new threads for larger bolts?
What parts do I need here?

Very nice work Mattias
You need to drill out the rivets holding the basket together to remove the backingplate and access the springs. Then drill out the holes where the rivets sat. i drilled out and fitted v-coil m10x1 thread inserts. There are people who say to drill and tap m8x1,25 directly in the existing holes, do NOT fall for that one, the diameter of the conical hole in the bigger end is larger than an m8x1,25mm bolt diameter is. A man in spain drilled to 10mm diamter and made steel insert from the inside that are glued, they are then threaded m6x1.

Bolts need to be either 10.9 or 12.9 quality.

You need 18 new bolts for the engine cover. a new gasket for the same,
You need 4 new springs.
 
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