R1200S Engine Mods

[wswartzwel]

Originally Posted by kpolito99

My R1216S is alive!

[omg1010]

Hello Kurt,

I also have the HP2S cooler on my 12S. I needed to shorten the oil-cooler hoses by approx 2 cm. I have taken large shims and longer screws (both stainless steel) to mount the cooler. All fits well. Just a bit tight with the front bracket of the fairing.

But without modification of the oil pump the effect is very minimal.

Brgds
Oliver

[J.Rose]

Originally Posted by kpolito99

I sure hope the new parts are worth the wait... .. .

I'm anxious to read about your impressions.

[kpolito99]

Got home from DeLand late this afternoon and just managed to unload and put the bike away before the rain started coming down.

First impressions are that the engine snaps to life more quickly than before and revs more easily. I didn't get to road test yet and plan to go for a short ride tomorrow morning before it gets too hot. I was told not to beat her too hard for a few hundred miles and to ride vary the engine speed continually.

I am expecting the extra capacity of the HP2S cooler to help keep the oil temperatures slightly lower and disperse any extra heat resulting from the increase in compression.

Attached are a few images of the tabs that I designed. Basically I am going to use the factory mounting locations on the front carrier to attach the tabs to the bike. Then I plan to insert screws through the new cooler into a second set of tapped holes in the tabs. I need to clamp everything into position and transfer punch the precise hole locations onto the tabs before I install the new cooler.

[kpolito99]

Just finished mounting the HP2 Sport oil cooler and then installed the plastic and went for about a 30 mile ride this evening. It has been hotter than hell in Tampa during the day but tonight we had a good breeze and the humidity seems to have lightened up.

Here are a few pics of the new cooler installed in the OEM location. The dimensions and mounting tabs are a little different so I tapped a couple holes in some thick aluminum plate and shortened the hoses.

BTW - I could not re-install the horn in the original location so I re-positioned the horn deeper inside the fairing. There was plenty of harness on the horn cabling so I mounted the horn bracket over top of the same fastener that is used to retain the intake snorkel. I forgot to try the horn while riding this evening but I assume it will work acceptably.

While tooling around and varying the engine speed with a few semi-hard bursts of acceleration the oil temperature never rose above 3 solid bars.







I really cannot offer a comprehensive ride report citing the performance improvement until after when I get the final Rexxer tune. The engine is noticeably smoother and revs more easily. Hard to say how much faster the bike is because I am not really beating on her too hard yet. I only have about 75 miles worth of run time on the new components.

My bike has always exhibited a bit of mirror shake at idle even after checking the valve adjustment. The mirrors are rock steady now while sitting a traffic lights while idling. It is hard to describe but it seems there is a lower frequency buzz now rather than the previous engine vibration which I recall.

Definitely looking forward to getting some miles on the new cylinders, piston rings and rod bearings so that I can pour the coals to her. I am absolutely loving the quick shifter and cannot wait to see if the front tire gets light now on the 2-3 shift under full power!

[sgoodwin]

Nice looking install, glad to see it's up & running finally. Now if it would just cool down enough to make it comfortable to ride life would be great.

[wswartzwel]

Nice job on the install.

[kpolito99]

Thanks gents!

Now I just need to find time to rack up some miles.

For those of you who are using synthetic motor oil, how many miles did you accrue before moving off the conventional 20W/50 engine oil?

[Milepost]

I usually do a drain and refill with the same kind of breakin oil after a few hours of running the engine. I will also do a recheck of the valve clearances, do a retorque on bolts/studs at that time. BTW... I cut open the old oil filter to see what kind of crap was left behind when it was opened up. Don't be surprised to find some lint and some very small non magnetic chips in the filter. First couple hundred miles I drive arond town or winding country roads, making sure I downshift thru all the gears to load and seat the rings. I then progressively run it harder and harder the next 300 - 500 miles and change out the breakin oil at 1200-1500 miles and then put in the synthetic oil. Be sure to cut open the filter again ... It should be pretty clean by then. If it looks trashy send in a few oz of old oil in to be analyzed. A good lab can tell you where the debris is from such as bearings, rings, pistons etc....

[omg1010]

Hi Kurt,

nice work! My HP2S cooler was "bolt-on" (using larger shims) and I did not have to displace the same ... You should accumulate at least 500 miles before getting to rexxer (as dyno runs with new pistons/conrods are not ideal).

I suppose you will be beyond 140 HP and thus the oil pump mod is recommended. Not because the oil temp needs to be lowered but because of increased oil pressure and increased flow-volume.

Brgds
Oliver

[sdfsds]

Or did you get the big bore done locally?

[Roby_Croatis]

i hope im posting this in right topic

this is my "home made" air filter

[kpolito99]

I am planning to put about 600 miles of mild use on the engine before making the trip to Rexxer.

Tom at Rennsport Motorrad in DeLand (shop owner who reassembled the engine) wants to see the bike again to re-torque the heads and adjust the valves before I complete the final tune.

While it would have definitely been less expensive and I wish I had done all of this work myself, it is just nice to have my bike back and have the opportunity to ride again. I had been riding the wife's SV650 from time to time and although it is a nice bike, it does not give me the same pleasure as riding the R1200S.

I am going to investigate fabricating the oil pump shim but do not plan to incorporate the change anytime soon. I have upgraded the oil pressure relief spring in addition to increasing the oil cooling capacity. Wossner did not feel that modifying the oil pump was a requirement and neither does Tom at Rennsport. Perhaps if I were racing the bike but as it is only intended for street use I do not plan to break into the oil pump at this time.

[omg1010]

Hi Kurt,

thats OK. The problem really comes only if you squeeze her to the limits and at high rpm. If you are just a cross country rider without race-track ambitions you don't need to worry.

Once you got her broken in and have gotten the rexxer done please post the results. I am having the pistons and conrods here but I am bit short of cash to get the cylinders done ...

Brgds
Oliver

[kpolito99]

Oliver,

Thanks for sharing your technical findings related to what the R1200S racers are doing in Germany to improve the performance of their engines.

Besides breaking in my Wossner components the only remaining mod I would like to make is to improve my factory airbox. Don't suppose you have any leads on where or how to obtain a set of Boxer Burners?

I have a Piper-X air filter and would like to improve the restrictive air horns before final tuning. Ideally I would like to make a run with the factory horns and then install an improved set and try to quantify the difference.

Keep us updated as well after you install your new components and I will do the same.

Kurt

Originally Posted by omg1010

Hi Kurt,

thats OK. The problem really comes only if you squeeze her to the limits and at high rpm. If you are just a cross country rider without race-track ambitions you don't need to worry.

Once you got her broken in and have gotten the rexxer done please post the results. I am having the pistons and conrods here but I am bit short of cash to get the cylinders done ...

Brgds
Oliver

[Milepost]

Very nice job Kurt! Glad it all worked out for you with the rod/ crank SNAFU. I plan to do similar engine mods next year, possibly with some cam changes and head porting.

You mentioned the boxer burners and I am interested in them too but can't find someone who sells them. Maybe we can get some help from our friends on the other side of the pond with acquiring some. I'm sure there are few other members here that would be interested in them too....Hmmm..Group buy??

If the Boxer burner can't be acquired then I suspect that someone has figured out how to make their own version using HP2S parts. Maybe Oliver can inquire on our behalf about the best current intake box/tract mods for the 1200S...

[omg1010]

Kurt,

the boxerburners for the R1200S you can get from Roesner & Rose or from Rehcing (please mail Andreas Reh - info@rehcing.com - and tell him that I gave you his contact details). Another source would be MKM Bikes (info@mkm-bikes.de).

This is what they look like http://www.s-boxer.de/threads/27299-einbau-boxerburner/page4

Brgds
Oliver

[omg1010]

Kurt, in the worst case and when you run into troubles obtaining the boxerburners please get back to me and I'll buy them for you and send them over by post.

Brgds
Oliver

[shreddr]

Originally Posted by omg1010

Kurt,

the boxerburners for the R1200S you can get from Roesner & Rose or from Rehcing (please mail Andreas Reh - info@rehcing.com - and tell him that I gave you his contact details). Another source would be MKM Bikes (info@mkm-bikes.de).

This is what they look like Einbau BoxerBurner - Seite 4 - S-Boxer-Forum

Brgds
Oliver

Good luck with that!

Also keep in mind this is an irreversible modification to the airbox, and they will increase the intake noise level. My seat of the pants evaluation of the BB's is that they are probably effective at 7000 rpm+ If that is where you spend most of your time then these will be a benefit, or if you are looking for a peak HP dyno number. I have thought about putting them in my HP, but numerous inquires have been fruitless. I did measure the R12S units so I have the dimensions if I wanted to fabricate my own. Make sure you read this:

https://translate.google.com/translate?sl=de&tl=en&js=y&prev=_t&hl=en&ie=UTF-8&u=http%3A%2F%2Fwww.s-boxer.de%2Fthreads%2F27299-einbau-boxerburner%3Fp%3D315438%23post315438&edit-text=

My $0.02 is you don't need them and won't notice them for sport/street riding, but I am sure you will do what you think you need to do.

[omg1010]

Boxer burner alone (with enriched fuel mix ...) result in 6-10 HP above 6000 rpm (without loss in torque).

Brgds
Oliver