R1200S DOHC Project

[Stephen400]

I spent a good 5 hours on Saturday working on the wiring loom. Boring but satisfying results.

Im adding cruise control from an rs/rt and i want it as close to 'factory' as possible so it was a great opportunity to route the 9 new wires through the loom from the battery area to the various end points.

This was at about 50%. It was dirty, sticky and dusty in parts. but the wires underneath were in excellent condition.

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Its going to look much nicer now alongside the powder coating.

Heres all the old tape

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and heres a photo of the bike outside for the first time, it looks awesome in the sun, looking forward to seeing it on a proper sunny day.

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I am getting a little concerned the paintwork is going to cover too much of the lovely stuff

I plan on getting the loom on and maybe getting it running this weekend. Then put the old fairings on and brainstorm colour schemes, if anyone has any suggestions I'm all ears. So far the obvious one is original scheme but black with purple stripes (if i can get a paint to match the powder) or maybe just a boatload of carbon fibre??

[Humbug]

I'm for the original in black and purple

[Stephen400]

Nice sunny day yesterday so I took the time to throw the fairings back on and get a sense of what its going to look like

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Wow, and black and white was the worst part in your opinion!

Am I tripping or does the Black and White go quite well??

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Got lots of decisions to make now. Akra silencer is no longer available new (Pretty sure they were available on BMW motorrad bohling when I first started work )

Looking at the Zard now, not many options left at all really and the Zard is still a bespoke single silencer. GPR do one but its just two normal silencers strapped together . Zard is available with an 8 week wait. Was hoping to take this bike to Germany in April, 8 weeks to be precise


I took a purple part to a local auto paint shop to see if they can make a match. Fingers crossed.

Still unsure about colour scheme. After staring at the bike outside for over an hour...

I can get Tekarbon side fairings and tail fairings for less than the cost of a decent paint job... Maybe carbon tail and sides, purple front, centre tank and pillion cover? Thinking I could paint those parts myself and even if the purple isnt a prefect match it will be far enough from the rest...

Any suggestions are welcome

[popsky]

I really like it the purple makes the paintwork shine. Stick with that for a while get the Zard, very nice bit of kit (but I’m a bit biased) imho it suits the bike without shouting I’ve got a trick pipe.

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[Humbug]

Black and white goes well I think. Maybe I'm biased but looks great with what you have done.

[Stephen400]

Sorry for the delayed updates, struggling to access the forum most days.

I really like it the purple makes the paintwork shine. Stick with that for a while get the Zard, very nice bit of kit (but I’m a bit biased) imho it suits the bike without shouting I’ve got a trick pipe.

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Yeah, the zard was the top choice but I'm taking the bike to a local exhaust builder to see about a custom solution. Even went as far as to cad design a silencer but there just isn't time before my trip. Hotels booked for 27th April (nice paintwork btw, looks really well)


Most of the work these past weeks have been mundane tasks, lots of checking and double checking, cleaning and installing little bits. Lots of stainless bolts, new Bridgestone S21s.

Started her up for the first time a couple of weeks ago, I was confident it would run ok but it was comforting to get confirmation!


I’m installing cruise control as it was one of my favourite features on my S thou. Really helps on long runs to relax your hands and arms for a bit.

There is very little space for extra anything on the S so I’ve had to go with a lithium battery (smaller + no orientation restrictions) mounted on its side leaving space for the cruise unit next to it. I designed and printed a box to keep everything in place, Also looks more ‘standard’ from underneath.

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Still unsure with the paintwork, I had a go at wrapping in carbon which has turned out great. Won’t know for certain until it’s all together but It will do for the trip and I can always pull it off and paint it stripy at a later date.

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The exhaust headers look great with a bit of colour in them!

[Stephen400]

Shes finished! (nearly)

Setting off to Germany at 5am on Saturday. I will make a post with more detail when I get back. Passed MOT today, Just a couple of small jobs to get done tomorrow.

Heres a few photos I took in the sun yesterday.

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[Humbug]

Technically amazing but the colours are not for me. Each to their own though. I did prefer the black and white over the carbon but like I say, personal preference.

[ianc53]

Well done, an amazing amount of work!
Hope you're enjoying your trip.

[Marcus_asparagus]

Wow, hope all is going well on your holibobs.

Couldn’t help notice the mirrors, are they off s1000rr and do they fit straight on?

Looking good so far!

Regards Mark.

[Stephen400]

Technically amazing but the colours are not for me. Each to their own though. I did prefer the black and white over the carbon but like I say, personal preference.

Totally get it, that’s the whole reason I did this. There isn’t a bike on the market that ticks all my boxes so I made one. Ideally I do want to add purple stripes on the side panels but for now I’m happy with how she looks.

First 1000 miles down, 89k to go!

Well done, an amazing amount of work!
Hope you're enjoying your trip.

Thanks very much, it’s been a lot of late nights but totally worth it. Trip has been fantastic thanks!

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Wow, hope all is going well on your holibobs.

Couldn’t help notice the mirrors, are they off s1000rr and do they fit straight on?

Looking good so far!

Regards Mark.

Yeah they’re Gen 5 RR mirrors, I wasn’t a fan of the originals. They needed indicators + prefer to use BMW parts over random aftermarket so gen 5 was the only suitable candidate. I did go for Chinese copies tho, I’m not made of money…

Not a direct fit, the bolt spacing is (off the top of my head) 10-12mm wider on the RR. After a couple of tests I went with using the original too hole and drilling a new bottom hole. I 3d printed a jig so both sides were the same. Had to shave a tiny bit of the fairing too but nothing serious.

The DRL in the indicator is non standard, I made those as they looked to be missing something.

I can give more details if anyone wants to try it too.

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they do look like they were supposed to go there.

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And the visibility is spot on!

Sorry for image quality I’m doing this on my phone in my hotel as it’s currently raining at the Nürburgring

Cheers

[andy griff]

As someone with the mechanical skills of a ( insert your favourite term for dunce here ) I think this is incredible. A beautiful bike. I loved my 1200S although it was bloody uncomfortable without bar risers and a one off version like this with useable upgrades must be a lovely thing to ride. Top marks

[Stephen400]

As someone with the mechanical skills of a ( insert your favourite term for dunce here ) I think this is incredible. A beautiful bike. I loved my 1200S although it was bloody uncomfortable without bar risers and a one off version like this with useable upgrades must be a lovely thing to ride. Top marks

Kind words, thank you

This has 1 inch bar risers which help a lot, I want to fit tank grips as they’ve always helped on previous bikes to take the weight off my wrists. But I don’t wanna cover up the carbon

I’m also adding cruise control which was a game changer on my s1000. It’s currently not working but when I figure it out it’ll be nearly perfect (for me at least)

[Stephen400]

Quick photo dump.

These are from my Instagram so have been edited slightly

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I love the Heritage M Badge, had to go with genuine for the side panels, the knock off ones are just slightly wrong, enough to bug me. This meant the only option was 74mm badges (original were 70mm, Heritage badge doesn’t come in 70 ) the 74 wouldn’t fit in the recess so I designed and printed some angled adaptors with led day running lights.

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The chineseum downpipes look stunning now they’ve had heat in them! And yea, that’s my thumb print I’ll polish them back to silver and run it up to get them coloured nice again.

Also added a badge to the alternator belt cover, there are holes there as if they were going to put a badge there but changed their minds.

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The vinyl wrap is amazing in the sunlight, there are tons of imperfections but they all seem to fade away when the light strikes it. Gorgeous.

I wasn’t sure but I’ve decided to wrap the rear hugger, which is already carbon… but it looks dated by comparison

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The seat has been recovered previously, ideally I’ll find an original one but there’s no rush there

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The mirrors are S1000RR 2019- (Chinese copies, I’m not made of money!)
The white honeycomb day running lights in the indicators are custom. There is just empty space otherwise

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The exhaust silencer was made by a local shop, it’s not exactly what I was looking for but I was on a tight schedule.

I designed and printed the end cap to make it look sleeker, it’s ok but needs refining. I want the steel tips to protrude the cap.

It’s printed in a plastic carbon fibre composite, heat resistant beyond 200 degrees. So far it’s never even been hot to the touch!

You’ll also notice the indicators under the fairing, again, designed and printed myself.

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Just picked up this Puig screen on eBay, £50, bargain. I’ve had a saved search for ages

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This photo shows how reflective the wrap is. Really top notch product, £150 for more than I needed for the whole bike.

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A few pics of the controls, the switch gears are standard housing, all the buttons were designed & printed myself (probably sick of reading that now eh?)

The Set and Res buttons are for the cruise control, which I couldn’t get working before my trip but I’m confident I’ll get there.

The buttons on the yoke control the mirrors and badge DRL (auto on but ‘switch offable’) CC turns the cruise on and off. LOW turns on the headlight manually (it’s automatic with daylight sensor, purely so the headlight drl is visible)

And obviously, had to make a purple key….

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The indicators are currently sequential, but I don’t like that you can see the individual leds, they’re also not overly bright on a sunny day… I plan on changing them to brighter leds without the sequential feature.

There’s probably more to come but this turned into a longer post than planned.

Any questions just ask!

[popsky]

Very impressive work.

Not jealous one little bit