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On the hunt for an early 1200GS (2005 - 2009) pre exhaust flap silencer. Don't need the entire pipe, just the back end.

:ROFLMAO: The problem is that when the bike is on the lift and the centers of the wheels are at chest height you cannot even see the dash, let alone the lights.

So, part of the weekend was spent stripping and inspecting the starter, with the rebuild/service being completed this morning. Some before and after. From this ... To this ... And this ... To this ... First test of the new starter fires the bike up within a few swings. However, it only...

Now starts quite easily. Just need to sort the pesky starter. But that's Monday's job.

If you don't have the proper tools to set it up again then, yes, it's best not to touch it. Once the butterflies, butterfly shafts and bushes are replaced though, the "factory settings" no longer apply, since nothing is as it was when it came out of the factory. Pretty straight forward to get...

Someone tried a fix for the idle stop screw, not very successfully though. Created a problem where the butterfly stop screw was holding on by about ½ turn of thread before falling out, which made adjustment impossible. This is what it is supposed to look like So quickly made a new stop An...

So, maybe the reason why the bike battled to start was because it was being smothered to death. With the airscrews turned out ¼ and ½ turn ( R and L respectively) and looking the way they do, I am surprised that you got it running at all.

Yup. I have replaced a few of those lower casings, and had the insurance write off a few bikes because of it.

My guess is that the chain was far too slack and ended up climbing onto the rear sprocket.

Apparently no master link. I have asked the client to bring in the chain so that I can have a look at it to firstly see what chain it is, and secondly to see how it broke. Probably going to find that it is some cheap chain "that I fitted myself!"

Yes, there is a case saver on there. However, the chain ended up between the case saver and the engine casing, which forced the case saver and the clutch slave cylinder (that bolts on over the case saver) away from the casing. It is therefore a little mangled. Insurance is refusing to pay for...

Thanks @Vilaishima. From which model is that starter? Is that one that you have or just a pic?

Correct. Tips and advice are always welcome, @Rufus115. I have had a look at a number of options. Yes, the SWM and Ducati starters are VERY similar. Unfortunately I don't have the option to swap out end caps as the bike arrived without a starter. Client purchased it from WBC as a non...

Nope. G450X mounting is different.

Nah, not my bike. Client's bike. That's why it's here, to be fixed. KTM where not prepared to weld it. They wanted to replace the casing which put it into write off territory.

The next project. One broken KTM 990. Chain broke and took out the clutch slave cylinder, which broke chunk out of the engine casing. Insurance wants to write the the bike off. And the bike only has 23000km on the clock.

Not really. If you are repairing the harness, chances are good that you already have the tank off. The most difficult part is removing the pins from the plug, but the correct tools makes it a lot easier. I just take a lot of photos of the plugs before I strip them to make sure I have a...

I do not use the plastic insulation tape anywhere, EVER! If I do cut into a harness or need to repair, I use the cloth/silk fabric tape, in particular the 3M fireproof one. The only thing I ever use the plastic insulation tape for is to protect the seals when sliding them over the top of fork...

Do NOT wrap them with tape. The individual wires must be able to move independently and freely inside the tubing, otherwise they break. Don't ask me how I know. The only way to do it correctly is the remove the pins from the plug and slide the cables into oversized heatshrink and reassemble...

You can thank me later! 😁