ToGGoT's BMW K100 Project

[ToGGoT]

So, yesterday i picked up my new baby. Well, maybe not picked, as much as scraped up the bits...

I've been looking about for a bigger bike to replace my 600, and wanted a bit of a tidy up project (Because i'm a cheapskate). Then, after missing a few or losing out on Ebay, i saw this 'bike' relisted after not selling at £625. Listed at £525, i made an offer of £430 not expecting much - only to get home from work to find an email saying "Yeah, i need the space, when can you collect?".

I almost fell off my chair.

I've just bought another bike. Bugger!

So, Saturday morning me and my stepdad load up the trailer, and head off from rainy Plymouth northwards, the 200 miles to Warwick!

Almost 4 hours later we rock up, and i enter the sellers garden, to find that the auction pictures had been kind. Very kind.

I was expecting the bike to have the fairing removed, however what i found was a bike badly in need of serious medical attention.

I quickly make the decision that as we've come all this way, and it looks at least salvageable I'll take it anyway.


So, we load up the bike, and head back. The sun shines all the way home - is this a sign?

Returning to Plymouth in the dark, we unload the bike into my garage, and slide the boxes in around it. I crash out.


This morning reveals what is to come:

https://i6.photobucket.com/albums/y204/ToGGoT/K100/Arrival2.jpg
I didnt know you could buy flat pack motorbikes...

https://i6.photobucket.com/albums/y204/ToGGoT/K100/Arrival.jpg
The frame is not in a good state. I think its just surface rust though.

https://i6.photobucket.com/albums/y204/ToGGoT/K100/Arrival10.jpg
Its been sat for a while. The tyres are gone, and flat, the exhaust is corroded.

https://i6.photobucket.com/albums/y204/ToGGoT/K100/Arrival14.jpg
The missus set to labelling everything!

https://i6.photobucket.com/albums/y204/ToGGoT/K100/Arrival12.jpg
The "Spares".

https://i6.photobucket.com/albums/y204/ToGGoT/K100/Arrival7.jpg
Cover missing, along with one injector... Think its in the spares box.

https://i6.photobucket.com/albums/y204/ToGGoT/K100/Arrival8.jpg
Looks suspiciously like Frenzy from transformers...


A check over the other parts shows the bike was last taxed in 1991... Ahem. This might be a bit bigger a project than i thought.

Ah well. So far, the parts i have discovered missing are the shift lever, and the rear brake reservoir.

Where are my spanners?

ToGGoT
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2005 BMW R1150R

[Sgoaty]

Looks like you have your hands full there. Best of luck!
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ZZR1400

[Gazdaman]

That'll be reet, it's a BMW after all.

It'll still be horrible to ride when it's done though mind. But hey, you can always sell it to some 50+ man.

Gaz

[Frost]

My dad had one. They don't wheelie, and to get it on the centre stand you have to be a bavaria named Hans with muscles on your muscles.

[ToGGoT]

Haha, cheers guys!

Will post up my project pics anyway! I dont mind being uncool!

ToGGoT
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2005 BMW R1150R

[ToGGoT]

Sooo, spent today working away. Still cant get the bloody exhaust off. Two of the nuts are round, and seized solid on the most awkward to get to of the down pipes.

Stripped all the switchgear off first as it was easy to do.
https://i6.photobucket.com/albums/y204/ToGGoT/K100/StrippedBars.jpg

Then pulled off the rear wheel, final drive, and had the shaft out, with help from Mr.Crowbar.
https://i6.photobucket.com/albums/y204/ToGGoT/K100/NoShaft.jpg

Looking sparse without all that extra weight!
https://i6.photobucket.com/albums/y204/ToGGoT/K100/Detail.jpg

Then, realised that the next step was probably engine out. It looked more difficult to drop the engine down than i could be bothered with, so i pulled the radiator and forks off, and lifted the frame off the top!lol!
https://i6.photobucket.com/albums/y204/ToGGoT/K100/FrameGone.jpg

ToGGoT
____________________
2005 BMW R1150R

[steveh]

As soon as i seen that picture i shouted "Oo0 TRANSFORMERS!!"


good find.
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Current : 06 Zx10r, 07 Wr450f SM, 74 850 norton commando, 63 bsa b40, 1962 Triton 650, 67 Triumph Tr6r, 1955 Triton 750, 1978 TY250E.

[Gazdaman]

Now get powder coating!

Gaz

[metal ken]

Brilliant bike,

I done mine up (if you can call it that) and beleive me it could wheelie.........though onlookers usually looked scared. Also if you stick a set of cams out of a K100RS 8v (if it is an 8 valve model) it will give you a few extra horses, also there is a chip you can get, mine was good for 160, and pulls in any gear

I found countersteering was the way to go round corners with these bikes. Still miss it though, want another one.

Good luck

https://i286.photobucket.com/albums/ll98/metal-ken/SP_A0043.jpg
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My motorbike breakers metalken.co.uk

Current bikes, GSXR750 Fighter, GSXR7/12, RD350 race rep, KH400

[metal ken]

PS, give me a shout if you need any bits, I have still got loads of spares....and they are not matt black

Ken
____________________
My motorbike breakers metalken.co.uk

Current bikes, GSXR750 Fighter, GSXR7/12, RD350 race rep, KH400

[Stevie B]

[metal ken]

as opposed to steering into the direction of the corner....why do you ask
____________________
My motorbike breakers metalken.co.uk

Current bikes, GSXR750 Fighter, GSXR7/12, RD350 race rep, KH400

[ToGGoT]

Thanks mate! I taught myself to countersteer with the GPX, so thats all cool. It is nice to see another one - i was beginning to feel all alone!lol!

More photos to upload later on when i get home.

Basically, the bottom end is seized. I've got it in bits, the head looks okish - really needs a clean down the ports. Will strip the valves out tonight.

Am soaking the pistons in the block in a layer of WD40, and have been suggested to do this again with diesel once its evaporated. The crank end bolt is only there to hold the rotor on, so im not happy about cranking it with a torque wrench, so freeing it up might take a while.

Otherwise, the strip down in pretty much there. Now to start cleaning, paint off and all that.

On another note, discovered this morning (Friendly guy in local BMW office) that the bike was originally BMW Baja red. Yik. Had wondered about the red tinge inside the mirrors/fairing.

I suspect it has been repainted with BMW Carabic Blue, but im not sure about that. Going to have to do some asking around, as i do like the colour!


Metal Ken: Have you got a gear lever, or rear brake fluid reservoir?

ToGGoT
____________________
2005 BMW R1150R

[numark1]

[Stevie B]

[Nixon]

[ms51ves3]

[metal ken]

[metal ken]

Well gave it a bash, went out on my GSXR, bit weary looking at which way the bars are when i steer round corners at speed, I do countersteer on some, but i steer into some corners aswel. Went at different speeds, and I take the bike right over.

Need to get one of those bike video camera things to have a good look.

Will give it a bash on one of the other bikes.
____________________
My motorbike breakers metalken.co.uk

Current bikes, GSXR750 Fighter, GSXR7/12, RD350 race rep, KH400

[ToGGoT]

Argh. I hurt all over.

Stripped the frame with Nitro-mors. Good stuff that. Burns you skin though. More rust under the paint in a fair few places, but nothing structural, so will repaint that, and thats good and done.

Soaked the cylinders and pistons in WD40, and have been tapping them with a block of wood and a soft faced hammer. It seems to have done the trick though, as the engine is now free, and turning nicely.

The clutch is FUBAR though. Literally had to destroy the cover plate to get it off, the friction plate has stuck fast, and is shagged, the spring bit doesnt, and im not certain about the back bit either. Thankfully i think Motorworks have got some second hand ones going fairly cheap so i'll chuck one of those in for the time being. The effort of getting it off has close to killed me though.

The auxillary shaft has taken a liking to the thread of the bolt that holds the alternator drive gear too. Heads come right off. Not sure how i'm getting that out, but i'm buggered if i'm buying another drive gear!

Anyhoo. Pictures from the last few days up later on.

ToGGoT
____________________
2005 BMW R1150R

[ToGGoT]

As promised:

Stripping the covers off.
https://i6.photobucket.com/albums/y204/ToGGoT/K100/EngineBreakdown2.jpg

Then cam chain and cams come out.
https://i6.photobucket.com/albums/y204/ToGGoT/K100/EngineBreakdown3.jpg

With the gearbox removed the clutch is in pristine condition...
https://i6.photobucket.com/albums/y204/ToGGoT/K100/EngineBreakdown10.jpg

And with the head off...
https://i6.photobucket.com/albums/y204/ToGGoT/K100/EngineBreakdown6.jpg

Then yesterday:

Clutch off finally.
https://i6.photobucket.com/albums/y204/ToGGoT/K100/Housingoff.jpg

Frame ready to striphttps://i6.photobucket.com/albums/y204/ToGGoT/K100/ReadytoStrip.jpg

And the Nitro-mors doing its job.
https://i6.photobucket.com/albums/y204/ToGGoT/K100/Stripper.jpg

ToGGoT
____________________
2005 BMW R1150R

[Gazdaman]

Impressive!

I can't stress the amazing finish you'll get with powder coating rather than painting. Much tougher finish, and I find it's about the same price if not cheaper than proper painting.

Just make sure you get the place to shotblast it first. Or make sure it's stripped back and you've sanded all the corrosion.

So get that frame down the powder coaters! And get it done black, you won't regret it.

This has the makings of a damn good project. Keep the photos coming.

Gaz

[Alexio]

Hmm, after looking at the picture with the head off I can't help but notice that both of those middle pistons are at top dead centre. Is this a typical firing sequence for an in-line 4 and what is most common for these types of engines?

Fantastic thread and project by the way! I wish I could find a project sometime in order to learn some more.
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will never give up his CG. I look at my fuel gauge more as a progress bar than a fuel gauge.
G: With my GSXR I do often effectively use it as a scooter with a clutch in town.
ms51ves3: why does it need 500 miles? Are you teaching it how to be a piston?

[ToGGoT]

Thanks guys.

Im torn 50/50 as to whether to powercoat it or not. On one hand i know a company fairly close that will do it, and sandblast it for me as well. On the other hand, a mate of mine recently stripped his frame, and repainted it with POR-15 rustproof, and Blackcote as a top coat.

If i did that i could do the forks, brakes, bars, headstock, as well as the engine and gearbox in the same gloss colour...

It does look very good, and according to the website its pretty good stuff. Either way it will be black!hehe!


The engine is a BMW Horizontal 4 design. Its actually based on a peugeot 104 engine way back, so its bombproof, but heavy and not that powerful.

Most 4-cylinder engines fire 1,3,4,2. This one is no exception to that!


Just getting together a shopping list to put in tomorrow. Think i'm going to opt for progressive fork springs because i dont doubt these ones are a bit tired.

Sidenote. BMW Parts are bloody expensive!lol!

ToGGoT
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2005 BMW R1150R

[Alexio]