Cam Sprocket Instal problem need Help

[davidb2]

I checked the cams and the right side (sitting on the bike) is down at 6 oclock. Could you have possibly had the engine on TDC on the exhaust stroke when you started this project? There is two tdc's, one compression, one exhaust. If you accidently started on the exhaust tdc then when you rotated the engine 180 degrees to do the other side, you would have everything 180 out and hit valves. Please note. I am not a expert and I do f&^%$ up sometimes. I would just like to help and would come over if you didnt live a hundred miles away. I am sure you will get it soon anyways.

[brad black]

well, tdc is both cylinders at the same time. on one side it is overlap, the other combustion. so, at any tdc, one will be 12, the other 6. given both plugs and injectors fire every rotation, it makes no difference.

if you set them both to 12 at any tdc, you'll have a big bang boxer. i've been curious to try that, just not on my bike.

[roger albert]

Yikes, that'd really wind the crank up. (and the crankcase pressure spikes) Would be interesting to see what happened to traction. The pulses on a regular boxer are already spaced and sized about like a big-bang L4, so this would be new.

Are you sure you were tdc at all on initial install?

[Jeff Williams]

Davidb2.
thanks for the look maybe we can have a bite at pier 23 in SF when Jenny and Rattus get their,( see thread). I'll get this beast running by this weekend and will ride up their to smooze with harold and jean. Maybe you can hit the Norcal- Socal ride April 3.
thanks
jw

Brad,
Thank you very much for your help.
If you check arround you will find that harleys make that sound
all kidding aside, thanks for the advice and patience.
jw

Roger,
at this point who knows. more than likely I wasn't even near TDC. What I know now is that I will be or I will have an expensive planter box for my house
Thanks for your help.
CYA
Jeff

[EZ-RIDER]

Hey Jeff;

e-mail me on the details of you problem, And about the ride on April 3 ?
Maybe I will ride down!!!!!!

[Jeff Williams]

EZ,
My problem is touching my bike when I shouldn't.
thanks for the offer.
see you April 3,(see email)
CYA
Jeff

[Jeff Williams]

Hi all,
Well I got the sprockets aligned and they seem to work well. spun the engine from the front pulley clockwise about a dozen times. Everything worked will, nothing moved, not nasty metal sounds. buttoned the heads up and put on the tank, charged the battery, set the motronic, and pushed the starter...OUCH METAL SOUNDS... The bike didn't start,(thank god). After some thought and a head butt to the wall, I pulled the valve covers, took off the tank, sprocket covers, and pulled the plugs. I then hit the starter again and a lite metal sound came from the chain galleys,(both sides), or the intakes very softly, I could not tell.
To review: in TDC, left sprocket cam notch at 12 o'clock, right sprocket cam notch at 6 o'clock. sprocket will advance cam 9 degrees. Sprockets in alignment.
I will more than likely adjust the valves after I check for misaligned chain rails,(check already), frozen tensioners, loose parts that don't belong, a compression check.
As I have said before, this sucks
Round #2 tomorrow pray for me or have a beer.
Jeff

[VetteRacer]

Got a beer in my hand right now for ya Jeff!
Hope you get it working soon. Ya know, so I can borrow it next time I am over there

Matt

[Jeff Williams]

Hi all,
well here is the story, I got the thing running. one cylindar was 180 off,(which fulfilled Brad Blacks dream of the big bang,single strock bike).
I started it and heard metal sounds when I started the bike but not when running. I looked in the hole which show you TDC and looked at the flywheel. 3 teeth were broken then I listened to the starter, it just spun with out moving the flywheel.
Bottom line: lost a flywheel and starter, ouch. Best of all called my local BMW shop ,(I have always heard a metal 'klunk' when the bike failed to start and kicked back), and they said that they did not know if this would be under warranty I would have to bring the bike and they would decide the issue. The problem is that I'm over 200miles away. If they didn't warranty the problem it would increase the over price of the mishap by at least 50%,(getting the bike their and back etc).
So I guess I will probly fix it myself as penance for being so stupid.
Thank you one and all for your insight and thoughts.
Jeff

[ckcarr]

"So I guess I will probly fix it myself as penance for being so stupid.
Thank you one and all for your insight and thoughts."

Its not penance. Its the cost of your BMW diploma from the school of hard knocks! I've got lots of those diplomas.

[davidb2]

I might have some parts if they fit.

[Jeff Williams]

ckcar,
i like the way you think.
It still hurts.

Davidb2,
thats a super lite bike you got there . Yes on the parts, I'll email you tomorrow, thanks.
Jeff
ps do you take cash

[motoyoyo]

Jeff, glad to hear you're almost out of the woods on your project. I had to laugh a bit though at the irony of a dentist working on a Beemer and ending up with three missing teeth... Can't you just put a bridge in to fix it?


davidb2....is that the new German version of the Mar's rover...?

[davidb2]

that is whats left of a 2002 GS, It is the donor for my cruiser.

[Jeff Williams]

Scott,
hahaha, I think I'm going for implants ( .) (. )
I will try to get this together asap so we can ride my friend.
cya

davidb2,
the starter may work but I don't know about the flywheel
will email you tomorrow
Jeff

[brad black]

so it tore the teeth off the ring gear as both cylinders came up to compression at the same time?

or was that not related? sounds pretty wild.

[Jeff Williams]

Brad,
yep, the single lunger was too much for the starter and flywheel, great sound, you must try it sometime. At TDC I set one cam sprocket at 12 and the other at 6. when I checked the valve adjustment both sides were opening and closing at the same time. I checked the sprockets again and they were at 6 and 12. One of the cylinders needed to be changed. I removed the sprocket from the right side and rotated the engine one revolution to TDC and installed the sprocket. Now both pins were at 12 o'clock I checked the valve adjustment after rotating the engine a few times clockwise and the adjustment was perfect at TDC. The pins on both cylinders stayed the same at 12. I was able to start the bike and it sounded good. I cann't say the same for the starter, lots of noise before it started. When I tried to start it again the bendix spring just spun and would not engage the flywheel.
Is the started shot or can the gear at the end be replaced. Are all the flywheels the same on the S, GS? What about the starters
CYA
Jeff

[VetteRacer]

Quick look in the ETK, shows the starter is the same for looks like most 94+ R's. The flywheel I guess is called a clutch housing, and is the same for the GS from 99+ and the R/RT/RS from 01+.
Starter part # is 12 41 2 306 700
Clutch housing art # is 21 21 7 666 246
Price listed for starter is 223, price for clutch housing is 153. Unfortunatly, I have no idea what currency that is, and if its dealer or MSRP.. but atleats shows the difference. LOL
Hope this helps you out... Goodluck Jeff
Matt

[VetteRacer]

Heres a diagram of the starter.



And heres the parts list for it.



Matt

[motoyoyo]

Matt, thanks for the ETK disk. It really comes in handy when you need part numbers and diagrams. I was able to order parts easily, for the last repair I did, using the part numbers from the ETK. Here is the other info Jeff will need for the ring gear (clutch housing).



and the parts list to go with it too:




Jeff, while your in there that far you ought to look into a heavy duty clutch replacement. You know you you love to do those 1st and 2nd gear wheelies....