If you happened to read my ride report from my Big Bend-Phoenix trip, you know I sustained a little damage. I figured I’d post on the status of the repairs here--a repair report instead of a ride report...

Jan. 8, 2006 - Disassembly
Today I pulled out the radiator. I was surprised at how simple this was. Looks like this now:

Here’s the damage to the radiator:

I also pulled out the oil pressure switch. I’m not sure if that thing is leaking between the rubber (plastic) and the metal nut or if it is leaking at the threads—in other words, does it need some thread goop (pipe tape). Regardless, it’s only $11 or so for the new switch. I’ll put the thread goop on when I reinstall the new switch.

I also made a first pass at cleaning up all of the oil and grime:

Before...

Stupid leaky switch...

After...

With new switch installed...

Much better... though I still need another bottle of Simple Green, a power washer and a bottle of blue-top Armor All Ultimate Clean Protectant.

I’m waiting for parts now--radiator, clutch lever, signal, mirror clamp bolt, oil pressure switch, RAM ball for the GPS, chain tensioner plates, yada yada yada. Oh yeah, need to tighten the SHBs too...

Jan. 9, 2006 - SHBs

Tightened up SHBs... they were quite loose.

Replaced the broken RAM ball; they replaced it under warranty.

Jan. 10, 2006 - Touratech vs. BMW Chain Tension Plates

My Chain Tension Plate... BMW part number 33177650081... which BMW calls a "Supporting Plate" in the parts fiche... went belly-up too. As you can see from the pictures below, the innards pulled out.

The field repair was to simply take the broken-off piece and use it as a washer on the outside of the plate. It looked like hell, but it worked.

A new plate from BMW is about $11 online. $11 for what though? A poorly designed POS aluminum plate that breaks? I don't think so...

I got to looking at the TT version... Chain Tension Plates F650GS, Part Number: 051-1206... about $30 for two plates. These are made from steel and have a nice finish on them. There are also holes on the tabs so you can screw the chain tensioner to the swing arm; you'd have to drill the holes in the swing arm and find the appropriately sized bolts though... I chose not to do this yet.

Here are some pictures of the failed BMW one and the TT one...

Click any image to enlarge it...

It comes with two bolts to replace the stock bolts, but I like the Torx bolts, so I kept them.

Looks like this installed...

The only minor complaint I could come up with is where the tabs mount to the plate. You can see it in the imperfection in the first and last pictures, but it's really nothing.

Jan. 21, 2006 - Warranty Stuff

Replaced lower right side subframe bolt.  The head of the old bolt was stripped from tightening too much (the bolt kept coming loose).

Replaced flasher on Hyperlite unit.  The blinker option quit working; Hyperlite replaced the flasher unit under warranty.

Jan. 25, 2006 - Running again!

Installed new radiator and by default put new coolant into the system (obviously).  It was a pretty simple task really.

Installed new clamp bolt for mirror, clutch lever and the new turn signal... again, uneventful

The oil pressure switch was also a breeze.  Put thread goop on the threads and tightened it down.  Hopefully that solves the oil leak issue.

I even got the old Red Devil started after not running in over 3 weeks... fired right up!  Just need a hose clamp...

Jan. 26, 2006 - The End!

Everything was pretty much done last night except for installing one hose clamp and putting all of the plastic back on. 

I also installed hockey puck on kickstand. 

Complete details and pictures here.

While I was messing with it, I also tightened up the kickstand.

And, that's it!  All damage and issues from my trip are complete...
... just like it never happened!