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Tank is stripped.

I'll need to find a floor Jack and lift it up.

Would the whole process take more than 2 hours?

I'm only doing all this to eliminate welding the two tabs...is this worth it?

Last edited by CaptainReza; 02-24-2015 at 09:36 AM..
Old 02-24-2015, 06:58 AM
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Here is a disassembly thread I did awhile back with some images that might help.

Neglected maintenance items to do this winter....
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Bill Swartzwelder
2002 R1100S Prep/2006 BMW R1200GS
1969 BSA StarFire
Old 02-24-2015, 07:07 AM
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if you search for motoyoyo clamps, you'll find a section with a good description of how to get that front end apart, including the special tool you need to fab.
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'04 R1100s. I changed a couple o' things.
Old 02-24-2015, 07:08 AM
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And here is one that shows the ball joint in the top triple clamp that requires heat to remove the nut..

MotoYoyo Clamps Installed
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Bill Swartzwelder
2002 R1100S Prep/2006 BMW R1200GS
1969 BSA StarFire
Old 02-24-2015, 07:10 AM
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Here is another subject with the same discussion: dismantle the handlebar
Old 02-24-2015, 07:23 AM
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Thank you so much guys...

The way i see it, do you agree or are you implying that welding it is better than the hassle of replacing it?
Old 02-24-2015, 08:30 AM
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doesnt matter don't weld it on the bike, take it off if you have it welded or replace it.
It is not a easy weld job I wouldn't consider doing it on the bike.
pretty easy decision get a quote on the weld vs used.
they are fairly easy to get out once the tank is off 20mins max
Old 02-24-2015, 03:09 PM
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Brent, i have access to a used one in perfect shape for $250. I also have a powerful impact wrench to perhaps undo that nut without heating. If it only takes 30 minutes to disassemble then I have no issues doing so, i thought it was real pain..
Old 02-24-2015, 03:37 PM
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The stud will turn in the ball joint… You have to hold it with an allen wrench while loosening the nut… A big impact will just spin the nut and the threaded stud it screws onto.

You do not have to remove the ball joint from the top triple clamp as you are reinstalling the old clamp to the new frame.
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1969 BSA StarFire

Last edited by wswartzwel; 02-24-2015 at 04:59 PM..
Old 02-24-2015, 04:51 PM
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Is this a cap that needs to somehow come off for me to see the nut and the Allen head screw?
Old 02-24-2015, 06:58 PM
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Also,what's the trick to access this nut?
If i lift the bike on a Jack,would it be enough?
Old 02-24-2015, 07:07 PM
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Is this the nut to undo?
Not sure how i can both hold the Allen head screw while using the socket wrench on at the same time...I'm completely lost...
Old 02-24-2015, 07:10 PM
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Old 02-24-2015, 07:11 PM
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That is why I said you needed to use a spark plug socket that has a hex on it for a wrench… you poke the allen wrench through the square hole, and turn the socket with a box end wrench. Or you can use a high offset box end wrench and an allen wrench...
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Bill Swartzwelder
2002 R1100S Prep/2006 BMW R1200GS
1969 BSA StarFire
Old 02-24-2015, 07:16 PM
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Quote:
Originally Posted by CaptainReza View Post
Is this a cap that needs to somehow come off for me to see the nut and the Allen head screw?

That is the ball joint… it will remain in the triple clamp… it unscrews out the other side.. but you do not need to remove it for what you are doing.
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Bill Swartzwelder
2002 R1100S Prep/2006 BMW R1200GS
1969 BSA StarFire
Old 02-24-2015, 07:19 PM
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Now i understand.
Sucks that i broke the bmw logo on top...that's probably another $30 lol
Old 02-24-2015, 07:19 PM
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Bill, how do I remove the other nut?

Bike is on center stand right now, but when i lift the front, it still doesn't clear that nut.
Old 02-24-2015, 07:21 PM
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This job is going to require some strength.. I see your hand in a cast in one of those images… would be good to let it heal before putting lots of force which is going to be required to get that nut from the underside of the frame loose.
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Bill Swartzwelder
2002 R1100S Prep/2006 BMW R1200GS
1969 BSA StarFire
Old 02-24-2015, 07:21 PM
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Quote:
Originally Posted by CaptainReza View Post
Bill, how do I remove the other nut?

Bike is on center stand right now, but when i lift the front, it still doesn't clear that nut.
When you take the shock loose it will move far enough to be out of the way.
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Bill Swartzwelder
2002 R1100S Prep/2006 BMW R1200GS
1969 BSA StarFire
Old 02-24-2015, 07:22 PM
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Where are you located? there may be a member from the board close by willing to help.
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Bill Swartzwelder
2002 R1100S Prep/2006 BMW R1200GS
1969 BSA StarFire
Old 02-24-2015, 07:23 PM
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