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So this little screw-up required that I make a new tool. Sigh! ;) Started off with a nice chunk of EN36, turned down to the correct diameter Added some marking dye And single pointed a 1.25mm pitch thread Drilled and reamed a 12mm hole down the center Then took it over to the...

I normally set them to the middle of the spec or slightly looser, never tighter.

Yup. Swingarm pivot went threadbound, despite plenty of heat.

AAARRRRGGHHHHHH!!! :mad:

Valve seats are a press/friction fit in the head. They are normally frozen and then pressed into place. https://www.enginebuildermag.com/2003/04/valve-seat-installation-procedures/

Correct. That went a little further though and damaged the barrels as well.

I suspect both bikes had been drowned. Both valves affected were lower RHS exhaust. That is the cylinder that draws water through deep water crossings. The sudden cooling of the valve seat causes it to shrink and fall out.

Had that happen to two different bikes, literally a few weeks apart. This one was off a bike with 83k on the clock, the other one was 129k

Here's a pic of an R1200GSA head where the valve seat has come loose. It can clearly be seen on the top right valve.

No, valve stem would remain the same length. The entire valve would move down due to the original spec valve thickness, albeit not as far as it would move down with new seats as well.

Possibly, but would need inspection. One can normally get away with just new valves and replacing the valve seat in the head. With any engine the valves recede into the valve seat due to the constant open/close contact, which is the reason that valve clearances need to be adjusted over time...

I get a call last night from a kid (well, he's probably 20) He has a Honda 125 Bros that won't start. He explains in great detail how he has rebuilt the motor and it ran fine for 2 days but now it's doing the same thing it was before he rebuilt it. Can I have a look? I say, Yes, bring it...

Well, I tried to quote it away, so have more than covered my costs for parts and labour. You know how "quoting it away" works. You throw out a ridiculous number, and if the client decides not to accept, then it's a bargain. He goes somewhere else. If he accepts, it's also a bargain! ;)

To be very honest, I did not expect that! The valves are truly embedded in the head, so much so that I had to skim the thinnest shim available, a 1.20 mm shim, down to 0.65 to get the correct clearance. There is still a lot of work to be done on the bike just to get it to where it can be...

The moment of truth has arrived. Will it fire up? :D:p:cool:

With the R1150/1100GS's in mind, I found this braided heatshrink, particularly for the wiring to the handlebar switch clusters. I still have to check, but I almost think it is large enough for the cluster plug to pass through. You then heat it like normal heatshrink. Here I have used it on...

Thanks to @sidetrack for the pointers to the wiring diagram. I couldn't find the Temp Sensor plug. Now that there is a new sensor fitted in place of the dowel, I needed to plug it in somewhere. Turns out the ignoramus that worked on it previously just cut the plug off (obviously he couldn't...

Thanks @sidetrack! That helped a lot.

Anyone have a wiring diagram for a Husky TE510? Or maybe someone with a 510 can just have a look at their harness and give me some pointers please.

I had someone come in a little while ago with his R1200GSA on the back of a bakkie. His brother had offered to service the bike for him. He couldn't get the oil filter loose (some people still don't understand what "hand tight" means) so he hit a screwdriver through it to try and turn it off...