BMW 1200GS/RT Alternator Belt Replacement 

Thank you NB. That sounds like a really good find🤩

Thank you so much for your comment Richard, I am so grateful and pleased it has worked for you. You will notice from a couple of comments that some have just wound the new belt on with no problem at all! I just do not know how they did that, I tried for 2 days and ended up splitting the new belt and had to wait another couple of days for a new one to arrive. I even thought I would order from Wunderlich USA their 'tool' for putting it on, but the cost and then the delivery AND then I normally get 10-20% import duty just made me stop and keep looking at the problem. The answer was staring me in the face, but that is often the case!

Hi Dub, that is brilliant news, I am so pleased it worked perfectly. Thank you 😊

Hi Edward, thank you so much for your comments. So pleased it worked for you… but of course I know it does 🥳

Even in the middle of desert you could change an alternator belt......as long as you have a 6mm bolt in your pocket and someone to turn the rear wheel!

Tony Markey thank you Tony for your encouraging comments.....have success when you do the job!

Thank you so much for your comment Chakothee🤩

Thank you Warren. So pleased it worked. Sometimes a simple method is the best eh🤗

That is such wonderful news Daniel, I am so pleased, thank you 😊

Thank you Fernand.....and it does work. After splitting the first new alternator belt, and my hand, I had to find another way🤗

Thank you GS ADV . Hope it helps one day🤗

Thank you Titan from Oregon, appreciate your comment!

Brilliant Greg....you are now a master 🤗

Thank you so much for your encouraging comment, so pleased it helped.

Thank you so much for your comment Armin. I am thrilled that it worked so well for you in the home of BMW.

So sorry you bike ate the belt…but sure you will install the new one with the bolt trick very quickly🤗

Just brilliant yughill, that is great news, it does work doesn't it. Although I never ever realised until a subscriber told me that there is an alternator belt that is 'elastic' and will stretch!

Thank you Christopher. I never thought of doing an alternator belt change while in the back of beyond, but if you had already tapped the holes and carried a spare belt and 6mm bolt and with a friend moving the back wheel in 6th gear you could easily change it! Great idea!

Thank you Norbert 🤩

Thank you Alex

I am so pleased Gav 🤩

Thank you Wade, I appreciate that very much.

Thank you Alessandro I am pleased you are enjoying it......

Hi Norman, your 1100GS is different. I am doing up an 1150GS now. Have a look at my latest videos Part 7

Hi I will thanks, my gs is in pretty good nick with only 30k . So just about to change brake hoses , fluids but wasn't sure what else the engine's quiet . Any thoughts ? BTW it would be interesting to see your workshop layout? I now need to see what you did about your sons engine. So sick on an immaculate bike like that. Thanks again.

Hi Norman, well rebuilding the 1200GS is like watching a box-set 😲 but I have a feeling this new project of a 2003 1150GS is going to take even longer. It has had 8 owners in its 18 year life, some appeared to care a lot, adding a full stainless bolt kit and Touratech parts, but alas others never did anything. Just changed to braided hoses and when I went to flush the ‘working’ ABS the Servo had decided to pack up🤷‍♂️😱. Looking at the colour of the brake fluid I don’t think it had ever been changed 🤷‍♂️. Hope yours doesn’t do the same. My workshop is too full really to work well, I have to wheel my RT out to give me the room. Just designed a cable stripper for my son Jason (of 1200GS fame) who has a washing machine rental business and spends hours stripping cable to get at the copper. So stepped back from the 1150GS for a week while I make all the parts for the cable stripping machine. You are always welcome to pop by if you live anywhere close, I am in Chesterfield. Norman

Thank you Rubens, it actually does work. You will see on the series of rebuilding that GS after the day engine blew up I replaced the alternator belt again on the new engine. Even easier before I installed the engine🥳

Thanks James, I am amazed that so many have viewed this video. There I was, after snapping a brand new belt, thinking ‘there must be another way’. Bit of a eureka moment🤗. Wish I could have another one 🤣

Normski soon as you used the plastic a was like that’s a right good idear that. Ya never stop learning.

Brilliant Serge I am so pleased it worked for you!

Great news Xaqueri and you are absolutely right about removing the crash bars!

Thank you Paul…so simple I kept staring at it for two days before the eureka moment 🤷🏼‍♂️

I was in despair Matthias, having split one new belt, trying to find a BMW tool even at that cost. Just had a cup of coffee and sat looking at the problem and it jumped out😮

Thank you Wilham 😍

No problem 😉

Thank you John🤗

Worked like a charm. On my 2010 GSA with the ESA suspension I had to machine down a 34mm socket shorter to fit between the crank pulley nut and the bottom shock mount.

Thanks John....wish I was 🤷‍♂️

I am so pleased Eric that it worked well for you. It is an easy method, well I found it was after breaking a couple of new belts after trying every other way possible😱

Thank you Sea Nomad, that is exactly what I was trying to do, find a method to replicate the BMW tool, and it does work 🤩

That is my most watched RU-vid video ever...seemed to solve a major problem, did with me anyway 🤣

So pleased the idea was of use WFO......it really does work!

Great idea Curtis....I try to keep the old belt just in as I need it again......as if you would 🤷‍♂️

Cliff Davies thanks for your comment Cliff and you are right you could cut the belt off but dead easy to wind it off🤗

Ha ha....well after two days of trying, splitting a brand new belt, looking for a BMW £300 tool....I sat having a coffee and thought, there has to be another way🤦‍♂️🤔

Thank you Francis, so pleased you liked the method.😀

Hi Rubens....very interesting questions and I must admit I do not really know the answers. The 2004 - 2007 GS had major issues with the ABS/Servo system. Jason's GS was perfect for about 18 months and then suddenly the ABS light comes on! Expensive at £500 to divert by professionals who have worked out how to do it and keep the warning lights correct. You are right that the latest bikes just get better and better but look at the cost. I bought my latest RT1200 2 years ago, and do all my servicing after the warranty ran out. When Mark Croft, the mobile tyre fitter comes to my garage to replace tyres, I always ask what he thinks of the BMW bikes. He was a Superbike mechanic for years travelling around the world with the teams. His feeling is that the Mark 1 GS, before 2004 is by far the best engineered bike. Like the first Long Way Round adventure. I would really like to have one of those but I notice good ones are increasing in price!

@@normanhill316 2007 does not have the servos.

I have the 2005 with servo. I bought it new and did everything by myself. No issue with ABS or servo.

Pleased you liked it Ralph🤗

Morning Matt, that is a really good question that I had never thought about. In reality, because I am not actually drilling the hole and the tap is taking a very tiny sliver of metal as it cuts the thread I doubt if it makes any difference, especially when you see the size of the counterweight balance at the other end of the crankshaft. However you have brought this up at the exact time. I am rebuilding the GS after it dropped a valve and destroyed the engine as you will see on my latest videos. I was going to tap one hole now I am going to do all 3 on the replacement engine.....watch out for that video. Thanks Matt🤗

That small amount of metal, possibly less thN 2 grains, not grams, grains, N imbalance wouldn't come into play unless spun to 40 ,000 rpm. Maybe not then. Very good thought though. Really shows your thoughts process. VERY THOROUGH.

Thank you Kevin that is so encouraging, especially after someone posted that it was a waste of time on Saturday. I tried to put a new belt on for two days before I came up with the bolt idea!

Hi Eddie, I do not have the bike anymore. But it was something like a 25mm. The plate that has the hole in it is probably about 3mm thick. Behind it is a space maybe 10-20mm no idea. Just screw in a bolt as far as you can with enough hanging out to feed the alternator belt around. Then remove the bolt and keep it safe for next time🤗

Hi Fabio, no modification, the hole is already there and all you are doing is cutting a thread which takes a few grams of swarf🤗. I do believe there are ‘flexible’ alternator belts that you can stretch.

Thank you Mike...every now and then you have a problem that takes you a couple of days to solve and then 🤗, it comes to you from absolutely nowhere.

I have just bought the same bike and steeling myself to do the maintenance! So your videos are really helpful. Cheers.

@@clunkygearbox go for it Mike…you will get to know and live the bike so much more🤗

Hi, me again. I hope you are OK. Would you believe it, the bike shredded the alternator belt! I feel confident I could sort it after your tutorial, but the garage said they will sort it under warranty and have a look at the useless fuel gauge. The battery tested ok and I have charged it and keep it trickle charged using a solar powered Optimate. My question is, is it OK to run the bike without it being charged by the alternator? It seemed to run OK when the warning light came on and got me home , about an hour's ride. Cheers.

@@clunkygearbox wow Mike it shredded the alternator belt😱. That sounds as if something is not aligned right and it is forcing it off. I am no electronics expert but I would not imagine you can do damage running the bike without an alternator, but thought it would run out of electrical juice pretty soon🤔😲

Thank you Salvador......hope the idea saves you stress, broken fingers....oh and money🤣

Hi Antimortem, excellent question and you are totally correct on pre 1200GS models. I have just finished 6 months rebuilding a 1150GS and the alternator belt is tensioned to 9nm. have a look: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE--nhB8wfgYuk.html at a different method I found that make the job so very much easier. But the 1200GS very hard to replace the belt but when you have it is a set tension, job done!

Thank you Rene….it works well 🤗

Well done Dana, sure you must work out at the Gym. I tried numerous times to do that without success

@@normski3091 I know, I was fully prepared for a battle! But bear in mind mine was on a different bike - R1200S. May have slightly different belt specs. Also, it was a 20 degree C day - I've seen some suggestions that leaving the belt out in the sun (maybe heating it with a hair dryer) may loosen it up. Glad to have your method in my back pocket for next time/next bike.

Dana Hooshmand yes Dana I think you are right a warmer belt would help. However the GS was so tight that the first time I tried I split the new belt and had to buy another one😱. Think it would had to be melted to get that one on🥵

Hi Antonio, thank you Antonio...I get a couple of comments saying it is just a waste of time and you just wind the new belt on! Well I tried that for two days, split one brand new belt....whoever can wind it on must be Tarzan!

Hi Spoon, I never had to remove the crankshaft gear pulley, just tap the threads with a 6mm tap in position. You would need a manual, such as Haynes manual for that model. I gave the manual to the new owner when I sold the bike. Sorry I cannot help you Spoon 😭

@@normski3091 I locked the engine with the TDC pin to remove the pulley nut. 140 NM to refit.

@@johnlang3233 perfect 🤗

Morning Beemer, good question but it is not a problem. It is a ‘plate’ of pressed steel maybe 3mm thick, so you can feel when you are through with the tap 🤗

@@normski3091 Many thanks

Hi Steve, that is a really good question. I actually used a rubber O ring only. Haynes manual says for 04-09 twins that when you take the speed sensor out take note of any shims in place as well as the O ring. There were not any when I completed my son’s 2005GS so I replaced the rubber O ring only and took it out for about 20 miles to check there were no oil leaks. I will upload a new RU-vid video today of my 2018 RT1200LC showing me changing the final drive oil. There is an O ring on the drain plug and a crush washer on the fill plug.

Normski Thanks BMW actually replied to day stating that I only needed the O ring.I thought I’d lost it. By the way used your advice on the alternator belt was great mine was really easy! Cheers

Steve carey thanks Steve. Great to hear your alternator belt went on well, brilliant news, thanks for the feedback! So tomorrow we can go riding again 😎. Oh maybe you live in Wales or Scotland 😳😩

Normski Ha no Lancashire

Steve carey I will wave as I pass you. I am in Derbyshire😎

Yes you can cut it but sometimes when you take it off it is a perfect belt! Handy to have as a spare.

@@normski3091 to have a spare I'd rather buy a second new one ;) Ride safe and have fun!

That does sound strange. I never thought of water getting in there but if the rear axle was full of water then it can get into the alternator belt area I suppose🤔 Pressure washers can do some terrible things. One blew the bike alarm on Jason’s 2005 GS to pieces, cost a lot to get it sorted! The Bike Alarm man did an amazing job on it otherwise it would have been scrap 😱

Normski - I don’t understand the rear axle comment. I think I just sprayed some soapy water into the drain hole at the bottom of this cover located at the front of the engine, behind the front fender area.

thebigbail It should dry out soon😳. Watch my video on the final drive ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-XN36pUz8t2E.html You will see that when I dropped down the rear axle it was full of water😳

Normski -Aaah yes, I understand what you are saying now....using the back axle as an example. I did my 10k service last fall and greased the shaft splines for that very reason. Thanks Norm!

Hi Gene, I just find Haynes good to work with. When I built a cafe racer 4 years ago from a BMW R100 the previous owner gave me his Cymer manual (is that what it is called?) , very good and lots of information, I did use them both.

@@normanhill316 Thank you very much for that Norm.

@@genowynn9273 Permafast for Stainless Bolts. I thought they were nation wide but maybe just here? www.permafast.co.uk. Also order online from Westfield Fasteners www.westfieldfasteners.co.uk

Hi Pascal, the belt for the 2012 GSA is 582mm which is longer than the 2005 GS belt. Contitech 482 I believe.

@@normski3091 Merci beaucoup pour le renseignement

Hi James, I will have a look if you want. Problem is when? Let me know when you are available 🤔

Normski a can drop it off and leve it with you if you like. It’s spluttering at low revs and the belt keeps pulling off had three belts on it.

@@jamessparrow6549 morning James, my email is: mrnormanhill@yahoo.co.uk if you can email me personally I can ask you some more questions.

Morning James, thinking about your alternator belt coming off is a real worry. I presume you have used my little trick and cut a 6mm thread so that you can screw in the bolt to hold on the belt while you wind it on. Then of course remove the bolt. For the belt to come off I imagine one of the pulleys is not running true or has been damaged🤔. My problem is that I have to take one of my bikes out of the garage to work on the other. I could not leave one outside overnight?. I also work remotely for a large organisation in South Africa 3 days a week so just cannot take a difficult job on. Can I suggest Mark Crofts who does mobile bike repairs and tyre fitting in Chesterfield. Mark is an ex World Superbike mechanic and is just amazing. He comes to you. His number is: 07971 197552 called MC Motorbike Services. There is also a new bike garage set up on Ward Street, Tupton and I hear he is excellent. Think it is called TL Motorbikes? Sorry to let you down James, but think these guys can really help.

Hi Carlos, search google for Big Blue Bike lift......also my video on it : ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-D9MqCaIS-8g.html

@@normski3091 thanks Norm, nice video's, have you ever taken the off the front cover off, the one behind the alternator belt?

@@CarlosTilbury no Carlos I have never needed to.....been in from the other end though, and that was difficult enough😳🤦‍♂️🥵

Hi Richard, I have been checking on Google but there seems so many different numbers I am not sure anymore. When I sold the bike I gave the new owner all the invoices for every part and the Haynes Manual. Researching it does appear that during 2007 BMW made a change but most people appear to be fitting the same belt as the 2005 model. There also seems more 'elastic' belts on the market now which will help, I imagine, to save time. Sorry I could not be more precise. I always bought from Motorworks in the UK who are so good and helpful and a quick email will be a good idea. www.motorworks.co.uk

Thanks Norman…I’ll send them an email! Take care and ride safe! 🏍️😊🇿🇦🍺

Ha ha that is a much better option 🤣🤣

Yes you can cut it, if you want, but it winds off no problem. You are right take out the spark plugs.

No need, it is so easy to to turn it off with a bit of plastic bottle 🤗