BMW R1200R R1150R/T F800 K1200R R1100R/T R1250R RnineT Message Board

Today while performing my second (2nd) valve adjust (2004 R1150R, 33,000 mi) I had wrapped up almost everything and was putting the (stock) plug back into timing port when lo, I shoved it all the way into the clutch housing Is there any way to fix this other than tearing everything down as if I were going to do a clutch replacement?

jaxter - According to a BMW shop that I visit, the plug will just fall to the bottom and stay there for the rest of your bikes life. Just go down to the local shop (or online) and purchase another plug and don't worry. As I understand it there is a plug used in a different model that will fill the void and not allow the user to push all the way through the hole, maybe others will chime in with the improved plug information.

I have heard the same thing. It falls to the bottom, and will just sit there. Just don't put a dozen down there.

I use the arrows on the cam chain sprokets to find TDC. with the valve cover off, you can see the arrow. That plug is a pain in the arse.

I think the trick to putting the plug back in is to hold it by the edges, rather than pushing on the middle. FWIW.

Thanx for the advice. I was looking at the service manual and thinking "Oh My oh My" or words to that effect. A quote from the "Valve Adjustment for Dummies"

Here is a list of stuff you should have on hand…
1. If you’ve still got the stock engine timing cover plug – go to BMW and get yourself a
REAL MAN’S plug from a R650-750-800-900-1000. They cost a buck. Go on. We’ll
wait right here. Where’s the fridge?

So that will be the new plug. Meanwhile a piece of duct tape to cover the hole?

If your dealer isn't real close, it may be worth it to pay for the shipping, or you could call Chicago BMW and get the 20% discount. But it may take 2-3 months to receive the part.

My 03 ran for over 3 years with duct tape over the hole.

Wayne

I recently went to the dealer with my timing hole plug in my hand...to get one of those so-called "better" replacement plugs. They said they had never heard of such a thing...and didn't show anything on a parts fiche except the one I had in my hand to show them. I just went home and put the one back in that came out. I think my next project will be to punch a small hole in the center of that plug and glue a handle of some kind into my small punched hole. That will give me something to hold onto when I push it back in.

Don't worry about it, I've lost at least one plug, possibly two (don't recall, I'm getting old and have a bad case of CRS). I ran with duct tape covering the hole for a while, but eventually it left a sticky residue. Being a fussbudget, I didn't want to leave that residue there, so next time I was at the dealer's I asked them to look up any old timing hole plug for an older Airhead. Lo and behold, they had one in stock for an R80 or R100-something that fits. And, it's larger, plus it's rubber, not plastic, and more flexible than the feeble little thing that came stock on our R. I haven't lost that one .... yet.

Here it is:

TDC plug, Bigger RT one . . . . P/N 11-11-1-744-327

It's fatter and thicker, but Darwin or Bubba could still push it thru the hole.

Since the hole in the casting is slightly oval with the top/bottom the bigger diameter, I start the plug at the 9 O'Clock position and with a screwdriver in the rubber groove at 3 O'Clock, push it inside the hole while another tool pushes in the center. Go slow. Be patient. Count the number of times it pops out as you're trying to work in the tight spot it occupies. Keep your eye on it when it flys! It bounces queitly.
.

jaxter wrote:Thanx for the advice. I was looking at the service manual and thinking "Oh My oh My" or words to that effect. A quote from the "Valve Adjustment for Dummies"

Here is a list of stuff you should have on hand…
1. If you’ve still got the stock engine timing cover plug – go to BMW and get yourself a
REAL MAN’S plug from a R650-750-800-900-1000. They cost a buck. Go on. We’ll
wait right here. Where’s the fridge?

So that will be the new plug. Meanwhile a piece of duct tape to cover the hole?

Duct tape is fine.

Using the arrows on the cam sprocket to find TDC will keep the rubber plug from getting pushed too far in.