[dmsantam]

I inspected the throttle pulleys on my 2005 hexhead GS (82,000km) after reading about the plastic cracking in other threads on here. Right side looks fine, no cracks. Unfortunately the left side has a single crack, in the inner circle shown in the mirror:

I did some research, and Munich Motorcycles in Perth (I'm from Sydney, Australia) has alloy replacement cams for $330 Australian dollars for the pair. That's about $220USDs. Seems to be some good pictures and a PDF sheet for instructions. Details here: https://www.munichmotorcycles.com.au/product/test/

I'll order those and be done with the issue once and for all. If you have any tips on fitting them, please feel free to pass them on.

cheers

 

[PerazziMx14]

Look like nice replacement units. I still would like if manufacturers of theirs metal replacements did not have them so stratospherically hight, it it really takes them out of the running for me. On your 2005 that means the original pulleys lated 18 years. So a replacement set should last very conservatively at least 1/2 that. A new set of pulleys is $56 from BIng and about and hour to fit them and drill/tap the shafts the 1st time. The beauty is once you drill and tap the shafts if you ever have to replace the pulleys again its only a few minute job and you do not have to pull the shaft. Simply unscrew the the hold down screw remove the broken pulley, slip on the new pulley and cinch down the hold down screw. I could do this 4X before I ever paid off one set of metal pulleys. Likely I'll not have the bike another 40 or 80 years to go through 4 sets of pulleys??

 

[icedog75]

Look like nice replacement units. I still would like if manufacturers of theirs metal replacements did not have them so stratospherically hight, it it really takes them out of the running for me. On your 2005 that means the original pulleys lated 18 years. So a replacement set should last very conservatively at least 1/2 that. A new set of pulleys is $56 from BIng and about and hour to fit them and drill/tap the shafts the 1st time. The beauty is once you drill and tap the shafts if you ever have to replace the pulleys again its only a few minute job and you do not have to pull the shaft. Simply unscrew the the hold down screw remove the broken pulley, slip on the new pulley and cinch down the hold down screw. I could do this 4X before I ever paid off one set of metal pulleys. Likely I'll not have the bike another 40 or 80 years to go through 4 sets of pulleys??

Hey Perazzi...facing the same issue on my 06....Assume you mean Bing...do you have the correct link handy for the pulleys? Tks.

 

[PerazziMx14]

You throttle bodies are type 77. Here is the link to either just the pulleys that will require you modify you existing shafts or you can buy new pulley and shafts.

Bing Throttle Bodies

Bing Throttle Bodies

bingcarburetor.com

My 1st set I bought pulleys and shafts then I realized that modding the existing shafts and fitting new pulleys is not too difficult and the price can be cut down by 2/3rds. Plus if you ever have to replace them again you do not have to disassemble the throttle body. Just undo the screw holding the pully on, replace the pulley and cinch down the screw.

Or you can go this route and all the heavy lifting is done for you.

Rebuilt Hex/Camhead throttle bodies for those...

These throttle bodies were stripped and cleaned then the butterfly shafts removed the old cable base pressed off the shaft then drilled and tapped to accept new Bing throttle cable pulleys. You will need to swap your TPS, injectors and stepper motors over to these but all are very easy to do...

www.r1200gs.info

 

[icedog75]

You throttle bodies are type 77. Here is the link to either just the pulleys that will require you modify you existing shafts or you can buy new pulley and shafts.

Bing Throttle Bodies

Bing Throttle Bodies

bingcarburetor.com

My 1st set I bought pulleys and shafts then I realized that modding the existing shafts and fitting new pulleys is not too difficult and the price can be cut down by 2/3rds. Plus if you ever have to replace them again you do not have to disassemble the throttle body. Just undo the screw holding the pully on, replace the pulley and cinch down the screw.

Or you can go this route and all the heavy lifting is done for you.

Rebuilt Hex/Camhead throttle bodies for those...

These throttle bodies were stripped and cleaned then the butterfly shafts removed the old cable base pressed off the shaft then drilled and tapped to accept new Bing throttle cable pulleys. You will need to swap your TPS, injectors and stepper motors over to these but all are very easy to do...

www.r1200gs.info

I'll take them and happy to send you mine in return....

 

[PerazziMx14]

Let me know where you want them shipped. I will send them out USPS priority so that shipping costs will be on the box.

Once you get them installed you can put $56 + the cost of shipping to you in the box with your old TB and then send everything back to me

Cheers,

P-14.

 

[icedog75]

OK...I hope to have a ship-to address later today....we're headed to Marfa on Wednesday so I'm going to have them sent to the shop.

 

[PerazziMx14]

As long as this is not a long drawn out process. If you are going on vacation or cannot get to this in short order, I'd prefer to keep the TB until you have time to do the swap. That way if someone else needs them in a pinch they are not sitting in a box waiting to be installed.

 

[icedog75]

If I don't have an answer from the mechanic in a couple hours...I'll just have you send them to my house. I don't want it drawn out either. I'm happy to send you $56 plus $20 for shipping right now....

 

[dmsantam]

I fitted the alloy throttle pulleys linked in my original post. It all went smoothly, the instructions on that website are top notch (see the pics in the link). The alloy pulleys also seem to be very nice units. They also come with new circlips. Taking the throttle bodies off also gave me the opportunity to clean them up nicely. Here are some pics which may help somebody else in future:

 

[icedog75]

I got a pair of TB's from PerazziMx14 with replaced cams....quite a nice job....they're being installed now. The alloy cams look really nice but compared to the Bing parts are a little on the spendy side...lifetime replacements for sure.

 

[PerazziMx14]

I got a pair of TB's from PerazziMx14 with replaced cams....quite a nice job....they're being installed now. The alloy cams look really nice but compared to the Bing parts are a little on the spendy side...lifetime replacements for sure.

If the $56 pulleys last as long as the originals, they will likely be lifetime as well. The nice thing now is if the replacements crack with the shaft being tapped replacement is only minutes and no need to disassemble the throttle body.

I hope they last a million and a billion smiles. Enjoy and ride safe.

To all the others once I get The other throttle body’s rebuilt they will be offer up to the next person who needs them.

Cheers,

P-14

 

[amsteldam92]

Guys I found this metal pulley kit on a good price on eBay , Etsy and Facebook Aluminium Throttle Cam ATC. According to the comments and feedbacks it seems this is very serious seller. I made an order , so now I'm waiting. Here are some pictures of them. It seems a quality part! Can't wait to repair.

 

[PerazziMx14]

With all the aluminium pulleys' the downside is you still have to disassembly the throttle body to install them. On the surface it looks like you simply bolt these aluminium pulleys on and go but the problem if the oldplactic pulley extends under metal stopper so it has to also be removed then a washer of the same thickness added to keep things shimmed out properly. Then the aluminium pulley is bolted on and everything is reassembled. For me its just as easy to drive off the old pulley stopper head off the shaft drill and tap it then fit e new pulley Bing for $56. Then in the future if you ever need to replace them again its simply remove a 8/32 screw pop off the old pulley and reinstall the new. No more throttle body disassembly needed.

Again I'm glad there are options out there but for me unless they can get competitive with price I'll stick with BIng original parts.

 

[amsteldam92]

Can't say the disassemble is a downside because is seems really easy. One time repair and no more thoughts about service is a great deal to pay the price. I like to travel a lot and such improvement save me from the same trouble. Sorry I can't give you the link but type Aluminium Throttle Cam ATC on Facebook and it will appear.
I see no downside just a better solution.

 

[PerazziMx14]

Can't say the disassemble is a downside because is seems really easy. One time repair and no more thoughts about service is a great deal to pay the price. I like to travel a lot and such improvement save me from the same trouble. Sorry I can't give you the link but type Aluminium Throttle Cam ATC on Facebook and it will appear.
I see no downside just a better solution.

Disassembly or more important reassembly is not hard if you are mechanically inclined. For some people airing up the tire is a monumental task so the thought of digging into a TB is like putting a man on the moon. For me the most technical part is removing the chrome cap on the right TB to expose the circlip so you can remove the shaft. But I have developed a surefire way to safely remove it and not damage it so it's reusable. OTher spent hours and end up mangeling it beyond repair.

I have done some tutorials and posted them on here and ADV Rider of the whole process. I just don't want people thinking that the metal pulleys are some how easier to install or less invasive as they really require about the same level of work as using Bing replacment parts.

 

[amsteldam92]

Making the thread in the middle of the shaft also need to disassemble the TB. Then you have to release it in order to fit the new part. After the new part is installed you're good to go till next time when it crack. This is two disadvantages. That is not an air filter to change it after certain miles.
This Bing repair kit is no different than wearing my shit pants again... Not a chance dude ! Better to ask a friend that is with crafty hands or mechanic to install the aluminium pulleys.

 

[PerazziMx14]

Making the thread in the middle of the shaft also need to disassemble the TB. Then you have to release it in order to fit the new part. After the new part is installed you're good to go till next time when it crack. This is two disadvantages. That is not an air filter to change it after certain miles.
This Bing repair kit is no different than wearing my shit pants again... Not a chance dude ! Better to ask a friend that is with crafty hands or mechanic to install the aluminium pulleys.

I never said that disassembly of the throttle body is not needed if replacing the pulleys the 1st time. Heck I posted a tutorials showing to how to take them apart and modify the pulley to accept replacement parts. However after after the shaft is drilled and tapped if you ever have to replace the pulley again you do not have to disassemble the throttle body again. Simply unbolt the old pulley, refit the new tighten down a screw and you are done. Is a 3 minute project.

As for longevity on average cracked pulleys we are dealing with are on bikes that are 15+ years old so if that is any sort of barometer we can expect conservatively that new pulleys will last at least 10 years. How many people on here have a 25+ year old bike regularly?? Also inspection is easy enough to do with a mirror, light and 30 seconds of time. Have a look every other oil change as part of your continued maintenance procedure. So if you are even the slightest bit diligent you can catch the crack in it infancy and mitigate the issue before a catastrophic failure happens.

I have nothing against the aluminium pulleys other than the cost. As I said before if there were competitively priced I'd buy them but at 4 to 8X (depending on what you buy) the
cost they are not worth it to me. I'll stick with the $56 option that need replace every decade or so.

 

[amsteldam92]

An Update from my previous comment!
Hello again to everyone.
So I did replace my cams with the aluminium from Bulgaria Etsy & website & eBay . I was too exited to take detailed photos but I will post what I have.
Well I needed something to guide me throught the process and I want to thank everybody that share information, you're the best. The ATC - Aliminium Throttle Cam has a facebook page has detailed photos on the process of replacing, to be honest they are very helpful ! I did clean the throttle bodies from dirt and fumes and after that I mount them back on the engine.
I think it was not that hard even for a person with low skilled hand like me. I made a test drive and the motorcycle runs great! It's nice to use WOT without fear of breaking a throttle cam!
Now I know that breaking cam in the corver or in the traffic is in the past, that makes me feel safe.
Hope I add an usefull info for everyone that are going to expirience this.
Check this video I uploaded on YouTube. Pulley works perfect!

 

[CallMeSnake]

Look like nice replacement units. I still would like if manufacturers of theirs metal replacements did not have them so stratospherically hight, it it really takes them out of the running for me. On your 2005 that means the original pulleys lated 18 years. So a replacement set should last very conservatively at least 1/2 that. A new set of pulleys is $56 from BIng and about and hour to fit them and drill/tap the shafts the 1st time. The beauty is once you drill and tap the shafts if you ever have to replace the pulleys again its only a few minute job and you do not have to pull the shaft. Simply unscrew the the hold down screw remove the broken pulley, slip on the new pulley and cinch down the hold down screw. I could do this 4X before I ever paid off one set of metal pulleys. Likely I'll not have the bike another 40 or 80 years to go through 4 sets of pulleys??

What you say is true, but for me, the opportunity cost of having the thing break at the wrong time far exceeds any savings. Imagine signing up for a motorcycle class, trip to another country, etc. and having the pulley fail at the start of it. Unless you replace the pulleys on a time basis to make sure they are always fresh, you are tempting the odds the longer the plastic pulley is on there. I'm replacing both sets on my bike with the Italian metal units even though the dealer put on one new throttle body just before I bought the bike. It's a shame that the manufacturer hasn't changed what it's made of to something that lasts like glass filled nylon.