800GS shock bolt design flaw?

Discussion in 'Parallel Universe' started by johngil, Jul 16, 2009.

  1. mustardfj40

    mustardfj40 Been here awhile

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    Apr 27, 2012
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    I quickly went through some 30 pages but couldn't find the order information on the Indy shock bolts, can someone please post the link the this Indy shock bolt? Thanks.
  2. ebrabaek

    ebrabaek Long timer

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    Just send Indy a pm.... He will give you the info.
  3. Indy Unlimited

    Indy Unlimited Long timer

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    Yeah PM or email me for a kit for your rear shock. I stock and ship worldwide.
  4. MCMXCIVRS

    MCMXCIVRS Long timer

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    Got my Ohlins front and rear on order and the kit is on its way too. Thanks Indy.

    I'll see how the bolt looks when I get to the install, haven't been too rough on the bike, but have been over lots of rough going fully loaded.
  5. Snowy

    Snowy Long timer

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    [​IMG]

    [​IMG]

    [​IMG]

    You can see the damage here in these pics. The bearing shell has dents in it from the rollers.

    So.....back to the drawing board.
  6. Snowy

    Snowy Long timer

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    I did get extremely airborne off a bridge on a dirt road last weekend.

    Funny stuff, wifey screamed for about a kilometre.
  7. Indy Unlimited

    Indy Unlimited Long timer

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    Hey Snowy, Looks to me like a clearance issue.
    The thin walled roller bearings looks to tight in the shock bore.
    This can cause the sleeve to not roll. That maybe why the dents are in one spot on the outside of the bearing. Are the dents on the outside of the bearings on the entire circumference or just one half?
    When installing a new set of bearings in the shock check that the sleeve spins in your hand. PM me if you want to reinstall a new kit for free.
  8. ccooper

    ccooper Adventurer

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    Come on BMW, fix this crap. Add another frame tab to shorten the distance of the top bolt (and maybe use thicker bolt) and problem solved. Simple and cheap and easy during frame manufacture. I still got my 2013 F800GS ordered, but I'm still really nervous about it. Indy, thanks for your PM's...I'll most likely order your kit when my bike comes in around April...if I don't cancel the order first.
  9. Indy Unlimited

    Indy Unlimited Long timer

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    We all know the stock set up is a weak design especially for off road use.
    I have over 750 Indy kits sold worldwide in the last 2 years and I will continue to offer a solution to fellow GS owners that love the bike.
    The Indy kit may not be perfect but is still better than bending the stock frame tabs or mount hardware and it won't damage your bike.
  10. ccooper

    ccooper Adventurer

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    Big thanks to you for doing the homework and spending the time to produce this solution. It makes my decision to purchase this bike a little easier. It just astounds me to why BMW hasn't already recognized this problem, engineered the fix (easy IMHO) and put it in production. For prior customers, they should at least offer your kit (or BMW's equivalent) installed under warranty to prevent any future problems. I'm sure the # of bikes affected by this is small, but if only a few, why not correct it when it's so easy.
  11. Snowy

    Snowy Long timer

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    I'm not sour on the kit. With the roads....tracks, loads and enthusiastic riding it's had something had to give.

    Everything worked fine until I changed the front end. Then I started riding on average about 15 - 20% faster.

    I think this is an end result of a few too many experiments with gravity.

    But wow it was fun.:lol3
  12. Snowy

    Snowy Long timer

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    The sleeve spun in the bearing perfectly prior to the free play being felt at the rear axle. Clearance was good, bearings pressed in really easy, they didn't come out anywhere near as easy.

    The rollers have been punched into the shell so hard they left dents in the bore in the shock. All positioned in such a way as to indicate that extreme compression occurred.

    I'm going to strip it down again this weekend and disconnect the electronics, cut the shock mounts off the frame and start from scratch and weld on some new ones.

    It's reached the point where I start cutting and welding.

    Such is life.
  13. Gaspare

    Gaspare Almost dirt rider

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    I do recommend to follow a specific welding procedure, proper for Manganese steel (our frame material).

    Since the Manganese steels have a tendency to become brittle if they undergo overheating followed by a slow cooling, during welding is a must to maintain interpass temperatures below 200 °C, carefully controlling the heat input and trying to take the following precautions:
    • avoid any kind of preheating
    • Use low current
    • deposit and cordons (sorry: don't know tech terminology) pulled quickly rather than slow and worked
    • If possible, work simultaneously on several components
    • apply water onto the workpiece during welding intervals to facilitate cooling.

    The weld joint must be made ​​with filler materials steels of the austenitic type in order to obtain a strong and tough joint.

    Good work :deal
  14. Indy Unlimited

    Indy Unlimited Long timer

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    Hey Snowy want to consider using a self lubricating bushing.
    I use them for the kits on the new WP shock which uses a 25 mm bore instead of the 26 mm bore on ohlins and others.
  15. cisco

    cisco old fat guy

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    This. I'll bet this will do the trick
    Cisco
  16. Indy Unlimited

    Indy Unlimited Long timer

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    Hey Snowy these bushings can do the job for your heavy duty off road riding for a bearing:

    Oilite 20x26x20

    http://www.amazon.com/gp/product/B0..._m=ATVPDKIKX0DER&pf_rd_r=0K570FWGHXSY4XHBX0DG

    It is a direct replacement for my needle bearing which is 20 x 26 x 20 as well.
    If interested I will buy a kit and send you 2 under warranty.

    I may just make all my aftermarket kits with self lubricating bushings based on your 2 up loaded riding experience.
    The stock shock has larger 28 mm bore for larger rollers.
    The aftermarket bores range from 26 mm to 25 mm depending on the shock brand and age. Seems like WP and Hyperpro are now using 25 mm bores.
  17. johngil

    johngil Reseda, CA

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    3,814
    While I no longer own my 800, I had the same wear patterns as Snowy with my kit. I just accepted the fact that I would need to frequently grease and every year or so replace my kit. The new bushing may be an improvement.
    I think Dan has done an amazing job of keeping the 800's of the world going strong.
    Nice work!
  18. Snowy

    Snowy Long timer

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    I was thinking a phosphur bronze bush, soaked in molly before install.
  19. petzi-baer

    petzi-baer Been here awhile

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    Jun 8, 2012
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    185
    So how is the frame looking?

    Petzi-baer
  20. Snowy

    Snowy Long timer

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    Dec 2, 2008
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    2,335
    Frame is fine. It rarely bottoms, even 2 up and airborne.

    The Ohlins had 2 revalves and 3 resprings. Currently running a 22.9kg/mm rear spring with about 12mm of preload.

    Fully loaded 2 up with gear sag is 70mm.

    The shock mount on the frame is slightly twisted from the bent shock bolts.