1150 GSA Drive Shaft removal and rebuild from BRUNO

Discussion in 'GS Boxers' started by et17smith, Apr 18, 2017.

  1. et17smith

    et17smith Adventurer

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    My 2003 1150 GSA is at 113k Kilometers.

    As a preventative measure I am removing the driveshaft and having new bearings with circlips and grease nipples installed by Bruno's Machine and Repair in Sudbury Canada. I will be driving across Canada on a tour with my band so I will be dropping it off and picking it up personally from Bruno.

    Here are some pics of the removal. (I will post pics of new driveshaft bearings in a few weeks). I had a relatively easy time removing final drive, swing arm and finally the driveshaft. While I was here, I removed the starter and Checked the play in the transmission input shaft splines (as I've heard this is a common failure). Thankfully there was very little play and everything seems to be in great shape.

    I replaced the final drive roller bearing 5k km ago.

    The custom "made in China" pivot bearing holder (BMW part #69) is there for comic relief.

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    #1
  2. et17smith

    et17smith Adventurer

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    #2
  3. et17smith

    et17smith Adventurer

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  4. et17smith

    et17smith Adventurer

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    Happy to answer any questions if you're trying to do this yourself and having issues.

    Also, I live in Toronto Canada if anyone is ever stuck here and needs some tools and space to work just get in touch. Happy to help out a fellow inmate.
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  5. IHMSAKIWI

    IHMSAKIWI Been here awhile

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    Hello ET,
    I have recently totally replaced the gearbox on my 2000 1150GS which was a marathon for me using this forum, Clymer and You Tube.
    I should have replaced the output shaft seal on the replacement gearbox as after 2000k's it has started a slow leak.
    Question: can I strip my bike down to the degree you have (without having to raise the sub-frame) and replace the seal? Is there sufficient space around the area to work on the seal?
    Cheers Peter
    #5
  6. et17smith

    et17smith Adventurer

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    Hey! Here are some pictures. If you also took off the rear shock you would have pretty good access to the output shaft IMHO. IMG_0106.JPG IMG_0107.JPG
    #6
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  7. gusable

    gusable Been here awhile

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    Excellent write up. Cool bike
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  8. IHMSAKIWI

    IHMSAKIWI Been here awhile

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    Thanks ET
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  9. Flyjpa

    Flyjpa Positive rate...GEAR UP!

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    I also rebuilt my GS driveshaft. Didn't use Bruno though because I was on a time crunch and he is a man with talents in high demand.

    Now would be a great time to replace your FD pivot bearings with some of MFOL's Nushings!

    I've had them on my GS now for approximately 1.5 yrs and close to 7K miles. They've been great. No issues.
    #9
  10. et17smith

    et17smith Adventurer

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    Thanks for the tip, but I actually just replaced those about 4K km ago when I had to put a new FD roller bearing. I used the pivot bearings from BMW as I was unaware of the nushings at that time. The next change will certainly be with nushings. Im hoping I won't have much issue with the driveline until about 200k on the bike.
    #10
  11. Flyjpa

    Flyjpa Positive rate...GEAR UP!

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    My driveshaft maintenance interval now: grease rear zerk when changing rear tires, which has been working out to be almost annually, probably overkill but I'm a bid CDO (OCD ISNT IN ALPHABETICAL ORDER :D). The forward will be done less regularly. The rear u-joint was the original culprit (notchy feeling when articulated, the front was still butter smooth) which required the rebuild at 54K miles in 2015 (13 years old at the time).

    My rebuilt DS u-joints (fwd and rear) came with standard zerks. I removed them and installed two set-screws in tandem to seal up the zerk hole when the DS is installed. Haven't had an issue with the set-screws loosening. I was thinking of using low profile fittings and using an injection needle to service, but decided to use what I had laying around my garage/shop.

    Lastly, when I installed my Nushings I didn't use loctite on my pivot pins. I used MFOL's instructions and BMW torque specs and placed witness marks on my pins and telelever to track any pin movement. Thus far they haven't moved a bit.

    Sorry for the long-winded reply. Hope this info is useful.

    Cheers!
    #11
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  12. et17smith

    et17smith Adventurer

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    Fantastic. Thanks for the info. Appreciate it
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  13. Flyjpa

    Flyjpa Positive rate...GEAR UP!

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    No problem! I've been told Bruno does great work, you'll be pleased with the product. Looking forward to seeing the install posts.

    Cheers!
    #13
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  14. et17smith

    et17smith Adventurer

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    My bike is back together and running as good as ever!

    Bruno did a fantastic job and is a wonderful man. Unfortunately he is battling cancer and is very weak right now with limited mobility and energy. I asked him about his interest in future work for Adv members. He said that he is happy to do driveshaft work for inmates, but won't be able to take on any other type of work until he is healthier.

    His shop is extremely interesting and super cool! He has a huge milling machine to cut shafts and splines that is powered by an old r60 airhead engine.

    The driveshaft has grease nipples on the front and rear U-joints. The front grease nipple remains on the shaft at all times, but the rear nipple needs to be installed when you grease it and removed when you install the driveshaft as there is no room for it when it's installed.

    It took me about 1.5 hours to put it all back together (from the swing arm back). Total cost was 390$ CDN. Let me know if anyone has any questions!

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  15. JimVonBaden

    JimVonBaden "Cool" Aid!

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    Looks great!

    Bummer about Bruno. I hope he gets well soon!
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  16. lewisjr1

    lewisjr1 Long timer

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    Thanks for the info. about Bruno. I've never dealt with or even met him, but for a very long time he's contributed to this forum and the larger Beemer community is ways big & small.

    In fact, there are very few that can compare in that regard. Luckily we some of them here.

    Godspeed to health & happiness for the man.
    #16
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  17. Flyjpa

    Flyjpa Positive rate...GEAR UP!

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    Sorry to hear about Bruno.

    Please pass my wishes for a full recovery. I'm sure most of the inmates here would feel likewise.

    Looks good! I wound up removing both zerks and using set screws to seal up.

    Now get that thing back together and get out on the road!:deal
    #17
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  18. et17smith

    et17smith Adventurer

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    I was on a trip across Canada with my band (www.unionduke.com). I had the bike back together and on the road within 24hours of being home! Brap brap!!!
    #18
  19. Flyjpa

    Flyjpa Positive rate...GEAR UP!

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    :clap:beer
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