K1200RS Exhaust Heat Shield Replacement

I recently replaced the aluminum cover part of the exhaust on my K1200RS. I had read on the BMW Internet Rider site that it hadn't been done before. Here is a quick description of how to do it:

1. Remove the rear wheel to allow access to the back side of the exhaust can.
2. Remove the 3 bolts holding the hanger place to the exhaust can, and the single nut holding the plate to the bracket. Set the plate aside for reassembly.
3. Remove the 4 TORX screws holding the black cap on the end of the can, and remove the cap. You may need to spray some WD40 or other penetrating oil around the seam to loosen the cap. Mine came off with a few light knocks with a rubber mallet.
4. Use a pair of vise grips and grip the edge of the can at the end of the pipe where the black endcap was. (note: this will mar the surface of the aluminum, so if you are intending to re-use the can, you might want to seek alternative means of gripping the canister.
5. Use a propane torch (not an oxy-acetylene torch - too hot!) and heat all around the end of the aluminum can where it meets the stainless steel catalytic converter. Careful not to burn the passenger peg mounting hardware, or the plastic fender/battery cover. After a good minute or two of heating, use a wooden or rubber mallet to strike the vise grip, knocking the canister off of the stainless steel inners. It may take a few reheats to get it all the way off.
6. When re-installing, slide the new can over the muffler, taking care to ALIGN THE HOLES FOR THE HANGER PLATE. This is tricky, as it is difficult to determine exactly where the screw holes are going to line up. I recommend taking a pencil, and marking a line down the can to the end, so you can visually line up the can with the screw holes as you slide it on. Careful not to twist the can as you push it down the muffler.
7. Heat the end of the replacement aluminum can. When it is all nice and toasty, quickly place the black end cap on the end of the can, and using a rubber mallet, carefully strike the cap to knock the can back in place. This is the only means I had of placing uniform pressure on the aluminum can to get it back in place. I know it sounds potentially destructive, but I completed the job with 4 re-heatings (I worked alone) and no damage to the bike.
   Take your time, and keep the aluminum nice and hot. You may want to lightly sand the inside edge of can end to facilitate ease of installation. Don't sand too much though, as you want a solid fit. There is nothing else clamping the cover in place.
8. To wrap up - simply rebolt the black end cap and hanger plate back on, replace the rear tire, and your done.