21 year old BMW K1200RS gets a new lease on life.

[JimVonBaden]

Picked this up from George at Gridlock Motors. It is in decent shape, but has sat for a few years.

George rode it down his driveway so I know it runs and moves. The brakes are useless without the servo, and it has some cosmetic damage that need attending to. I suspect I will do a refresh, fox or eliminate the ABS, and a full service on it. Should be interesting.











Some serious rust, but only on the stands. Maybe it was parked in dirt.


George built this from scraps. The only thing he had to buy was the petcock. He has over 1000 miles on it since he built it.

 

[SandRdr]

Just getting broke in! Another fix n flip?

 

[FLrider]

Cool project 😎

 

[JimVonBaden]

Just getting broke in! Another fix n flip?

Yeah, not really my kind of bike. But it will be a great bike for the next guy once I am done with it.

 

[EuroMoto]

I just missed a 2003 K1200GT recently, I'll be following. I believe it and the RS are the same bike with different bars and pegs but not sure.

 

[JimVonBaden]

I just missed a 2003 K1200GT recently, I'll be following. I believe it and the RS are the same bike with different bars and pegs but not sure.

Pretty much the same. George has a GT available also for $700. https://www.flickr.com/photos/14907...lJKdt6wCzI5LMk-NGzygGxvdIrSlE_8oVbbrkxJP327Vw

 

[JimVonBaden]

Picked it up today from George.


He threw in a NOS instrument cover. The PO had a brake fluid leak that went all over it and the windscreen.




V-Technic Screen and main fairing stay for mounts.




Also a spare seat to practice my seat covering.


I also ordered a battery for it, and am looking for a set of factory panniers, and condition.

 

[JimVonBaden]

Finally got it into the garage.



I was busy with this:

 

[JimVonBaden]

Found some panniers for $200. Ironically they are from the K1200GT George is also selling. Scratched up, but solid.

 

[SandRdr]

That bike would be awesome with boost!

 

[JimVonBaden]

That bike would be awesome with boost!

Yes it would. It is already 130hp.

 

[JimVonBaden]

I started the bike today, just got back from a work trip and the battery came in. Runs great, but the ABS runs all the time. That said, the brakes work and the servos are activated when the brake is pressed and the lever pulled, so I am gaining confidence that it is fixable.

Started whole, ended naked.







The oil plater cover is leaking pretty badly.






Rusty center and sidestand:



Tried my hand at plastic repair. It came out decent and strong:

 

[JimVonBaden]

I started the bike today, just got back from a work trip and the battery came in. Runs great, but the ABS runs all the time. That said, the brakes work and the servos are activated when the brake is pressed and the lever pulled, so I am gaining confidence that it is fixable.

Started whole, ended naked.







The oil plate cover is leaking pretty badly.






Rusty center and sidestand:



Tried my hand at plastic repair. It came out decent and strong:

 

[JimVonBaden]

Lower mount too. I found out that I couldn't stitch through epaxy, so I had to grind it off first.





I replaced the faceplate for the instruments. It had brake fluid damage:



Then cleaned up the parts:





Check out how much gravel is in the bottom tupperware:

 

[FLrider]

Quite a bit of work but it seems to be coming along nicely 👍👍

 

[JimVonBaden]

Quite a bit of work but it seems to be coming along nicely 👍👍

That is the easy stuff. The ABS repair may prove harder. I also need to find the right color paint. Mostly this is a bike in good shape.

Thanks,

 

[ZoomerP]

Lower mount too. I found out that I couldn't stitch through epaxy, so I had to grind it off first.





I replaced the faceplate for the instruments. It had brake fluid damage:



Then cleaned up the parts:





Check out how much gravel is in the bottom tupperware:

Looks like asphalt.

That is the easy stuff. The ABS repair may prove harder. I also need to find the right color paint. Mostly this is a bike in good shape.

Judging from some of your past projects, it's going to be a very happy bike.

 

[FLrider]

That is the easy stuff. The ABS repair may prove harder. I also need to find the right color paint. Mostly this is a bike in good shape.

Thanks,

You’re welcome 👍 Those early ABS systems are a love/hate relationship. Most of the problems came from not flushing the system on an annual basis. Moisture was the main culprit for malfunctioning systems. Living in a humid area I flush the brakes on all my vehicles once a year as it is cheaper to spend a few $$ on a bottle of brake fluid then buying a new ABS unit

 

[JimVonBaden]

Spent a few minutes rekeying the panniers and removing the lids for future paint.

Key in, locked pannier, and push in the tab to release the locking tab and pull the tumbler out:




Original key in and you can see all the pins are pulled in except the locking tab.






Pull out the key and all the tabs extend:


Here is with the new key and old tabs:

Note how none of them are flush.

Now remove each key tab and lay it in position where it came out, not critical, but you want to make sure you do not accidentally remove the spring too. Wipe them off to see the numbers on them.



Now the tedious part, sort of. Insert the new key while one at a time installing the key tabs until you can match as many as possible with what you have. I managed 4 matching, three is enough. Matching means the tabs do not stick out either side and are perfectly flush.

Keep a record of the positions and numbers for the other pannier.


When done, all the tabs should be flush on both side except the retaining tab at the end.


Make sure you remove the extra springs to prevent binding.


Lube the tumbler and key tabs. This makes for smooth movement, and helps retain the tabs during installation.


With the key in, push the tumbler in while twisting. The retaining tab will retract allowing the tumbler to be installed and locked in place.

Now, do the same with the other. Similar with the top box.

This works on all system cases for the R1100 series and K1200 RS/GS/LT/GT and R1200C/CL/CLC.

 

[ZoomerP]

Neat to see how to "re-pin" the cores.