DIY 18K service

[AdzventureXR]

Should be able to use screw driver to compress clamp which will release the lock, or pliers.

[Chris61]

Originally Posted by Chris_T

Great !
Thank you.

Any tips on removing the existing clamps ?

Hi Chri_T
Could you confirm details of the new clamps when you have sorced some, all dimensions, make and where from please.

[smithy]

Originally Posted by Chris61

Hi Chri_T
Could you confirm details of the new clamps when you have sorced some, all dimensions, make and where from please.

I just used some stainless "thin" (7 or 9mm wide) jubilee clips from fleabay. Much easier to do than the silly BMW clips. I've even heard of people using heavy duty "zip ties" with no issues.

Smithy.

[Chris61]

Originally Posted by smithy

I just used some stainless "thin" (7 or 9mm wide) jubilee clips from fleabay. Much easier to do than the silly BMW clips. I've even heard of people using heavy duty "zip ties" with no issues.

Smithy.

What is the diameter of clamps/jubilee clips?

[bazzer]

I bought the alpha racing replacement clamps that bolt on for the throttle bodies.

[Chris_T]

Originally Posted by Chris61

Hi Chri_T
Could you confirm details of the new clamps when you have sorced some, all dimensions, make and where from please.

I've measured the clamps on the bike as 8.5mm. I already had some jubilee clips from Toolstation for my Mondeo turbo hose, but these are 11.5mm. The diameter of 50mm to 70mm would have been fine, but as they are too wide I'm going to order the Alpha Racing clamps, details from XR God.

Meanwhile, I need the bike, so I've put it all back together again. The whole process was easy but very time consuming, especially the last part which is fitting the cockpit covers. There are 3 different types of bolt used on the fairing and I made a short reference sheet with their locations and that really speeded up re-assembly.

[Chris_T]

Thank you bazzer, smithy, and AdzventureXR for all your help.

[Chris61]

I have now completed the 18,000 mile major service  Many thanks for all your help and advice 
The  most involved job was removal and reinstalling items to access the rockerbox cover, it took hours. Well.... start to finish took about 5 hours each of the four days, thats 20 hours, so how a dealer can do it in one day I just don't know 
  Checking the valve clearances was straight forward with no adjustment required. Existing rubber gasket cleaned up and refitted.
I managed to purchase four stainless steel clamps totalling £9.95 for the throttle bodies 9mm wide 50 to 70mm diameter which worked fine. Total cost for all items £153.
Now... the SERVICE reminder on the dash needs sorting. I will take the bike to a local bike mechanic who has an APP on his phone, plugs it into the bike to reset the service reminder and clear any showing faults.

Questions... Do the throttle bodies need resetting? and is it necessary to bleed the ABS modulator?

[SimonUK]

Originally Posted by Chris61

I have now completed the 18,000 mile major service  Many thanks for all your help and advice 
The  most involved job was removal and reinstalling items to access the rockerbox cover, it took hours. Well.... start to finish took about 5 hours each of the four days, thats 20 hours, so how a dealer can do it in one day I just don't know 
  Checking the valve clearances was straight forward with no adjustment required. Existing rubber gasket cleaned up and refitted.
I managed to purchase four stainless steel clamps totalling £9.95 for the throttle bodies 9mm wide 50 to 70mm diameter which worked fine. Total cost for all items £153.
Now... the SERVICE reminder on the dash needs sorting. I will take the bike to a local bike mechanic who has an APP on his phone, plugs it into the bike to reset the service reminder and clear any showing faults.

Questions... Do the throttle bodies need resetting? and is it necessary to bleed the ABS modulator?

If you local bike mechanic has the app and can reset the throttle adaptation it is not goin got hurt. If you did no work on the brakes during service than there is no need to anything with the ABS.

[Antares]

What Simon said, if you're doing your own service it might be well worth investing in Motoscan and a compatible scanner like UCSI-2100, total cost is about 80 quid and you can do all the diagnostics, reset service, service functions, adaptations etc on your own bike, it's well worth it long term. Re adaptations: it should be fine but I personally always reset everything each time I did even an oil change on the bike, takes 2 minutes and doesn't hurt.