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"KRS/GT" Technical Q&A K1200RS/GT Technical Questions/Answers

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  #1  
Old 02-02-2014, 02:25 PM
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BMW K1200RS/GT Starter removal w/some cleaning.

On the clock....start time, starter was out in less than an hour and I had "cranking" about 5 hours later. With the BMW/Clymer method....I'd probably still be in there.




Shop temp in Celsius. Nice balmy winter day:




Starter....good luck even seeing it in there.

Disconnect the battery.

First remove the seat rail/fuse holder bracket and push the fuse holders out of the way.

Remove the plastic cap over the alternator wire and disconnect the blue wire. NOTE: the ground wires/terminals you see on the pic aren't OEM BMW so won't look like your bike. Don't use my pic as a referral, take your own if just to make sure everything goes back as it was.

Then you can see something:



Disconnect and remove the coils, pay attention to the location of the spark plug wires/ground wire to the coil and ziptie things out of the way.

Next you may want to disconnect the O2 sensor,sidestand switch and gear indicator switch. All them wires run alongside the frame L/H side of the starter. I did not disconnect them and I should have.



Now I can see the starter from the side:




Long ball end wrenches, remove the 3 bolts...two holding the starter/main ground/coil ground and the smaller one for the frame ground.Main ground wire and the bolts:



Remove the plastic protector cap on the starter and disconnect the wire.

Starter is now loose. Pull it back and that's where I almost abandonned the job. It was stuck in the bellhousing and I couldn't pull it back. Had to go warm up by the woodstove and think about that one for a few minutes.

Back to the shop and some lube directed at the starter nose/boss on the bellhousing and some twisting/turning/pulling and it came out.

And that's where it gets tricky. You have to turn the starter and bring the rear in exactly this position and that will free the nose/gear from the bellhousing providing no clearance issues as explained later:




And when it is positioned as per the above pic, it should look like that at the front:





A little bit more pulling/twisting should free it and it should fall in your hands:





Well that's a big maybe. Mine came out easy enough as I knew it would, I have done that before. But I couldn't easily reinstall it this time, piddled around with that for a few minutes, pulled it out and fixed the clearance issues with the file. And if you do that job....get them darn O2 sensor/switches wires out of the way, they'll catch on the starter terminal when installing.

Had to learn to paint today so pic shows in red where I had issues. They may differ from bike to bike but that's the ones to watch for:





Installation is the reverse, went right back in after I fixed the slight clearance issues.

The fun part...bolting the starter back in place....ground wires...etc etc. And installing the protective caps on the starter wire/alternator wire. I'll let you guys figure that one out unless you want to learn some French cuss words.

I'll do a "Part II" on the starter inspection/cleaning in the next few days.

Yes Richard....here is some Kootenay salted dirt for you, had to paint where the yellow plating had corroded and apply Rub'n'Buff to the Aluminium end caps.

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Old 02-02-2014, 02:40 PM
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Re: BMW K1200RS/GT Starter removal w/some cleaning.

Pierre,
Great write-up and good pictures - thank you!

I am sure this will help K1200RS owners who plan to do the Starter, but not at same time as the clutch or output shaft seal/o-ring job.

QUESTION: Did you have to remove some metal from the RED spots in one of your picture ?
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Old 02-02-2014, 02:59 PM
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Re: BMW K1200RS/GT Starter removal w/some cleaning.

Quote:
Originally Posted by sailor
Pierre,
Great write-up and good pictures - thank you!

I am sure this will help K1200RS owners who plan to do the Starter, but not at same time as the clutch or output shaft seal/o-ring job.

QUESTION: Did you have to remove some metal from the RED spots in one of your picture ?

Yes very little metal.Cleaned up the rough casting at the alternator...then maybe -1mm at the alternator pole and some smoothening up at the bellhousing casing at an angle so the outside line is intact.

No need to dremel or grind, a few passes with Grandpa's Canadian Nicholson file. I was a bit surprised by that because I had done it before without filing anything. But sure made the installation smoother....so smooth that it even surprised me, it slid right in.
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Old 02-02-2014, 05:17 PM
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Re: BMW K1200RS/GT Starter removal w/some cleaning.

Very nice and helpful write up with pictures. Thanks for taking the time to document the process. I have some of those German milling machines you utilized for metal removal.
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Old 02-03-2014, 03:42 AM
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Re: BMW K1200RS/GT Starter removal w/some cleaning.

Yes Pierre, nice work, and certainly cleaner than my butchered job, but I was keen to "go where no man has gone before" and find an alternative to lifting the frame. Years back when I did my starter removal exercise, the thought of lifting the frame was too much to consider as an option. Your method better than mine as there is no dremel work involved.
And, I guess this should end up as a sticky too. Must be winter where you are and too much free time on your hands. Me? I'm just workin, ridin, and fishin, and to hell with everything else.
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Old 02-03-2014, 07:55 AM
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Question Re: BMW K1200RS/GT Starter removal w/some cleaning.

What lead you to remove the starter (for us non mechanics).

Symptoms/reason for diagnosis.
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Old 02-03-2014, 09:41 AM
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Re: BMW K1200RS/GT Starter removal w/some cleaning.

Quote:
Originally Posted by BMW
What lead you to remove the starter (for us non mechanics).

Symptoms/reason for diagnosis.

I am anal-preventive, no need for electrical gremlins on the road. Ask Richard for the symptoms, he got me in there way back then.

But just to be contrary to the manuals/BMW procedures, was worth the effort to me.

Free time????....You bet! They told me to take extra leave.
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Old 02-03-2014, 01:53 PM
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Re: BMW K1200RS/GT Starter removal w/some cleaning.

Nice write-up. Thanks for aking the time to take pictures and post a write-up. One day or another we'll have to consult it...
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Old 02-03-2014, 02:13 PM
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Re: BMW K1200RS/GT Starter removal w/some cleaning.

Thanks again Pierre! I've made the thread a sticky! If you do the starter clean up you can add it to this thread, or start a new one!
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Old 02-03-2014, 02:54 PM
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Re: BMW K1200RS/GT Starter removal w/some cleaning.

Quote:
Originally Posted by CJS350
Thanks again Pierre! I've made the thread a sticky! If you do the starter clean up you can add it to this thread, or start a new one!

Thanks...I tried to do the Part II, starter cleaning but can't upload pics today. Google +...
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2003 K1200 RS at 53 (Oh Yeah......over 6000RPM)
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Old 02-10-2017, 01:57 PM
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Re: BMW K1200RS/GT Starter removal w/some cleaning.

Time to bump my thread...

If anyone cleaning their starter finds oil inside,the housing assembly (nose?) seal may have failed.

N/A from BMW but shown in the parts fiche with the housing assembly.No 6 under starter in the parts fiche.Also N/A from BMW.

So N/A means no specs given as to the size of the seal.And mounted as it is in the assembly,no way to read the seal markings.Wouldn't matter anyway the OEM seal isn't even marked as to size.And hard to measure in place.

Seal is Honda part number:91204-GK8-003.Common to a lot of Hondas so should be available.Approx $2.50 at the not so local Honda dealer and in stock.+$4.00 on Amazon.

Made in Japan the Honda seal so perfectly applicable to the BMW Japanese starter.

Size is 15x24X5

OEM markings? NOK ACO5821
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Yamaha RD200 at 16
Yamaha RD350 at 17
Honda CB750F at 18
Honda V45 Sabre at 24
85 BMW K100RS at 28 (Very nice and sorely missed)
90 BMW R100GS at 34 (Too slow, too cranky)
2003 K1200 RS at 53 (Oh Yeah......over 6000RPM)
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