Scrambler Modification programme

I have ordered most parts by now but many are yet to arrive.

The first thing I started working on is the GS mudguard with a Rizoma license plate holder.
I am quite happy with the way it has turned out after scratching my head as to how to attach the plate to the guard.

I still have to see how best to route the cable through the arm of the mudguard.

Next week end I will probably work on what will come in place of the diving board at the back.
Will post some pics once I have something to show...

Thanks Rems.

Hi coron2u,
Sure.

First you will need the BMW Parts for the GS Mudguard:

• Mudguard GS 1200 - Part # 46 62 7 682 884
• Mudguard mount bracket - Part # 46 62 7 671 618
• Screw for rear mudguard M6x65 - Part # 46 62 7 688 883
• Screw m6x20 - Part # 07 12 9 904 073
• Rear mudguard washer - Part # 46 62 8 543 238

The license plate holder I chose is the Rizoma ref PT081B in 100x162 mm.
It comes with a LED light but without a reflector, so you may need to ask your reseller to order one too although I have no reference for this part.

Then you will need to buy the bits and pieces to put the mudguard and the license plate holder together:

• 4x Black aluminium countersunk head bolts M6 x 25mm
• 4x Plastic 10mm long x 10mm ext diameter x 6mm int diameter spacers
• 4x Plastic M6 washers
• 4x Rubber well nuts
• 1x Rubber pass through cable grommet - 5mm int diameter for a 3mm wall thickness

For the tools, I used a 13mm wood drill bit (for the well nuts) and an 8mm metal drill bit (for the pass through grommet). Before drilling with the wood drill bit a did a pre hole with a 3mm metal bit.
I also used an x-acto knife to clean the holes' edges after the drilling was done.

You will need to make a template for the location of the holes and tape it to the mudguard to precisely drill it.

I attach a few pictures that will hopefully illustrate the process and the needed parts.
I still need to work out the routing of the electric cable to the light.
Let me know if you need more info.

So, after a little break I have received most of the parts needed and will start working on the bike!!
So far I have the following:

• BMW Single seat + BMW painted seat cover
• BMW black cylinder heads
• Unit Garage handlebar mirrors
• BMW NineT Racer handlebar clamps (neater than leaving the ones with a thread for the original mirrors)
• Kellermann Bullet 1000 PL for the front and Bullet 1000 DF for the back
• Rizoma under tail cover ZBW048B
• Rizoma electric wiring EE104-01
• BMW GS Mudguard + Rizoma PT081B license plate holder
• Luis Moto battery tray to remove the airbox
• K&N RE-0960 filter
• K&N 62-1340 breather filter
• Wunderlich right side bag

I am actually still waiting for the airbox removal "kit" and for the gaz tank cap.
I have plenty of bits and pieces to put everything together such as cables, plugs, caps, etc so do not hesitate to ask if you have questions.

I attach a couple of pictures illustrating what needs to get on the bike!!

Cheers - Silaxe

So here we are, I have now received all the bits and pieces but am no longer with my bike as I have relocated away from Paris in the context of the current crisis. Anyhow, managed to do a few things before I had to leave and here is my progress below. It is a bit long but hey since I cannot fix or ride my bike, I enjoy writing about it .

GS Mudguard and License plate holder
A bit of info updating what was written above. Getting al the parts right is actually a pain as there is no manual as to what you end up needing.

I received the reflector bracket and the reflector after a lot of waiting.
There are 2 shapes for the bracket with the same reference (PT533-05-VE-B) ?!
And there are 2 references for the reflector:
- EE141-01 for the one with round corners
- EE045-01 for the one with square corners

While I prefer the bracket which does not come forward, the one I received actually seems to work better as it gives more room behind it for the nut that ties the reflector... I also replaced the nut with a black one.
Now that I have plenty of time before I attach anything to the bike I'll see if I manage to order the other version of the bracket.

What is tricky is the fact that the two little bolts holding the reflector bracket to the plate holder are right at the level of where the mudguard protrudes. So when I initially put everything together and started shaking and banging the whole set-up to see how it held together, the bolts were hitting the mudguard .
So I removed the washers and shortened the tiny bolts so they would come flush on the other side, went for slightly longer spacers too, 11mm for the top and bottom ones and 12mm for the two on the sides and put two washers on the bottom bolt. Note that compared to what was written above, I changed the bolts from 25mm to 30mm.
Now the whole set-up no longer rattles when I abuse it although let's see if this is the case once it is on the bike.

On the inside I finally found a way to attach and route the plate light cable.
I used bowden cable clips (ref 51 21 7 040 546) which I shortened and hot glued to the mudguard.
I would have liked to pass the cable fully through the arm of the guard but unfortunately there is not enough space inside on the whole length so I made a small opening where it becomes large enough. The material is extremely hard and the best way was to initially drill and then clean up the opening with a cutter.
The outcome is quite clean and the cable is well protected.

I used an indicator connector for the end of the cable and prepared a 125cm cable to connect the license plate light to the tail tidy set-up. The cable will follow the side arm along the brake line and then into the underseat tray.

More info on the next post.

Tail Tidy
The next thing I managed to (almost) finish is my tail tidy.
I have used the Rizoma under tail cover, Kellermann Bullet 1000 DF black indicators and the Rizoma electric wiring (Ref EE104-01). I also bought a rear wiring harness from BMW (ref 61 11 8 548 705) to get everything ready while I still used my bike.

There are plenty of bits and pieces needed to have a "tidy" set up.
I got BMW indicator connectors (ref 61 12 7 699 594), rubber nut covers from Rizoma (ref RB-084), cable sheath, special zip ties that attach to the little "winglets" (BMW ref 34 32 7 708 473), rubber plugs for the unneeded holes and a plastic bracket (ref 61 13 8 365 536) to clip the Rizoma connector for the brake, position and plate lights.
I have soldered all cables and used shrink tubing to make things clean. I have also used a black fabric tape where I was worried about chaffing (ref 83 30 0 402 345).

I have tested the set-up and it works!! and no error lights.
Once I have everything finalised it will be plug and play.

More info in the next post.

Airbox / Intake silencer elimination
This is mostly prep work as the main thing that needs to happen is the removal of the airbox.
I will cut it as I have no intention do disassemble the bike.
I finally decided to get a power tool to do that and bought a Proxxon long neck mini grinder.



Before I cut through it though I intend to Dyno my bike in stock configuration and with the filters mounted on the intakes. Some said they'd do it but I have not found any results anywhere .

The main work was preparing the temperature sensor to be able to relocate it in the left filter. I have followed @TiM81 's post and he provided much needed advice to get to the right result. I have published what I have done on his thread but will consolidate here.

The sensor is a bit bulky and needs to be ground to become circular in shape. I cut off the excess plastic and then protected the tip and inserted it in my wireless drill to sand it at high speed.
I then painted it for a better finish.

I have selected K&N filters ref RE-0960. I like that model as the cap is matt black with the K&N logo.



This is the way the sensor will be inserted in the filter

The wall of the filter is very thick and the groove (where the green o-ring sits initially) needs to be widened from 3.5 to 6mm for the notch to sit properly on the other side of the wall.

For reference, the tip of the sensor is 9mm in diameter and the groove falls to 8mm in diameter. The notch is grinded down from 13mm to 10mm.

The hole drilled is 8.5/9mm although I used a 10mm drill bit to make it. It is placed 6.5mm from the edge of the flange so that the whole sensor sits fine against the flange once inserted in the filter.

The next thing I prepared is the extension of the crankcase breather hose with a filter at the end.
I used another original BMW hose (ref 11 15 7 712 578) and a couple of connectors (22-22mm and 22-16mm).
The filter is a K&N ref 62-1340.

The battery relocation bracket is from Luismoto. I prefer it to the other options as it is quite hidden once in place.

The foam padding seems a bit flimsy and the nuts and bolts could be better. I replaced them with black ones with a flange. (got them from car bolts.co.uk). I may also put some rubber washer between the bracket and the bike's frame if the clearance permits it.




Voila - Not much more to add at this stage. Will update soon hopefully...