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TheSmiler
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PostPosted: 21:04 - 05 Oct 2015    Post subject: Reply with quote
jimbopea wrote:
Gearbox shat itself catastrophically, rear shock is shot and it needs a new drive shaft. I've kept telling myself for the last year ill make it roadworthy, but another winter is coming and it's still sat there Sad

If i was going to fix it i'd want a recon gearbox, decent shock and a refurb shaft. last time i looked it would cost more than a running one sells for!

But as i said, its not going anywhere so if you do at any point need any bits its there.


Ouch that's quite a small but expensive list. Though this is more than likely going to cost more than a running bike, heck I'm using this for experience more than anything though. Prefer hands on.

I'll have to check parts against my bike to see if they will fit. If my engine is working then I can move onto body parts and that will be the coolant cap and tail light. But I'm not sure if I should go after market for the tail light. Guess I will see how it goes. Coolant cap could be the same though depending on year. Wink
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TheSmiler
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PostPosted: 15:06 - 06 Oct 2015    Post subject: Reply with quote
Well it wasn't that bad weather wise so I thought I'd try and fill the oil up and then get the bike started. Now that my much needed part has arrived. However didn't go quite to plan Found out that a crank case bolt has snapped, which means I'm going have to do some DIY with it. This crank case bolt held the fairing on so obviously as it went down the fairing snapped off and so did part of the bolt.

Also tried my R1100RS Seat on the k100RS to see what it would look like.

https://i.imgur.com/iCT8lEHl.jpg

https://i.imgur.com/uHTKM2pl.jpg

Ordered some bolts and will be getting to it on the weekend, see where I stand.
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TheSmiler
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PostPosted: 16:07 - 09 Oct 2015    Post subject: Reply with quote
Well update time, weather has been kind post less so. I'm still waiting on some parts. However I did have a crack at the crank case bolt. Now as you can see from the image above it looked like it was going to cause some problems.

Didn't seem to be the case I pulled the crank case off simple bolts and two jubilee clips holding the water pipe on. And was presented with the problem.

On a side note considering this was found on it's side with no/little oil left inside. There doesn't seem to be any visual damage at all. However that isn't saying there won't be.

https://i.imgur.com/jyEed1tl.jpg

Had a go with normal pliers at first however didn't have any result didn't think it would. Then tried mole grips no go couldn't get enough on it. So I used a small flat bladed screwdriver and knocked it gently in the gap between the case and the bolt. Then tried the mole grips again voilà. Came straight out easily.


https://i.imgur.com/sdUZEk3l.jpg

Crank case is back on and now just waiting for the bolts to arrive. I don't want to go ghetto and make some up. Don't really have any at the moment anyway.

Right now I'm waiting for bolts might as well do something else so I started on a side project for the bike. Managed to get this piece of metal from Marmalade. He wasn't really using it Laughing

https://i.imgur.com/dEBWlcxl.jpg

And using my new Dremel 3000 (don't you just love new tools?) I used a few of the grinding discs two in fact so far and created this below. As you can see from the image it's not the cleanest of cuts but it still has more work to do on it.

https://i.imgur.com/bW4X490l.jpg%20

Right now an update on the look of the bike plus few other minor things that have been done, I've removed the clocks and headlight bracket. I've purchased a new 7 inch headlight and brackets to fit the bike. Also removed the rear foot pegs, these were annoying to come off and were rusted. So used the Dremel to chop the ends off and pulled them straight out.

https://i.imgur.com/LWdJsCUl.jpg
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Matt B
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PostPosted: 09:19 - 11 Oct 2015    Post subject: Reply with quote
TheSmiler wrote:
https://i.imgur.com/dEBWlcxl.jpg


What is this for?
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TheSmiler
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PostPosted: 10:05 - 11 Oct 2015    Post subject: Reply with quote
Matt B wrote:
TheSmiler wrote:
https://i.imgur.com/dEBWlcxl.jpg


What is this for?


You will just have to wait and see. Still has more work to do on it yet.
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Matt B
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PostPosted: 10:59 - 11 Oct 2015    Post subject: Reply with quote
I hope it's a flame thrower attachment.

Edit - if that is a bit of Killalot's old silencer be careful, the K100 may reject the implant due to incompatibility of a superior machine Wink
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Fisty
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PostPosted: 00:54 - 12 Oct 2015    Post subject: Reply with quote
Have you checked it runs yet?
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TheSmiler
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PostPosted: 06:52 - 12 Oct 2015    Post subject: Reply with quote
Fisty wrote:
Have you checked it runs yet?


As I said I'm waiting for the crank case bolts to arrive don't want to make any up and the tank. The tank was late on the delivery date should be here in the next few days/today.
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Undinist
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PostPosted: 12:44 - 12 Oct 2015    Post subject: Reply with quote
I'm not happy to hear your K was nicked Smiler. Crying or Very sad I also ride a scruffy old K and I think of them as of zero interest to thieves. I leave mine on the street in South London with no anti-theft devices. What area do you live in? Was the bike nicked for joyriding or getting home from the pub or something?
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TheSmiler
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PostPosted: 14:51 - 12 Oct 2015    Post subject: Reply with quote
Undinist wrote:
I'm not happy to hear your K was nicked Smiler. Crying or Very sad I also ride a scruffy old K and I think of them as of zero interest to thieves. I leave mine on the street in South London with no anti-theft devices. What area do you live in? Was the bike nicked for joyriding or getting home from the pub or something?


Yeah well so did I but thieves around this area at the moment are stealing any bike they can find in Bristol. Lucky I've got an almax on it at the moment.

Anyway update time...

I've found a little snag and a new lesson has been learned. Lesson first;

Don't expect something to be easy/assume you are free of broken bolts. Always check both sides if your bike has been stolen/crashed

Now update;

K on the inside, if I was going to go steam-punk this is the kind of bike you would do it on and make a clear crank case cover.

https://i.imgur.com/DawE2wrl.jpg

Now a close up of the bolt, going have a think on this and work out the best course of action.

https://i.imgur.com/moFJUV5l.jpg
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P.
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PostPosted: 15:10 - 12 Oct 2015    Post subject: Reply with quote
You could have checked it runs before buying anything though... Thumbs Up
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TheSmiler
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PostPosted: 15:32 - 12 Oct 2015    Post subject: Reply with quote
Paddy. wrote:
You could have checked it runs before buying anything though... Thumbs Up


That will be the second lesson, though as I said this is all about learning, I don't mind going into the engine.
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chris-red
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PostPosted: 15:43 - 12 Oct 2015    Post subject: Reply with quote
Could you just replace the cam cap?
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TheSmiler
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PostPosted: 15:51 - 12 Oct 2015    Post subject: Reply with quote
chris-red wrote:
Could you just replace the cam cap?


I was going to do this however apparently.

"cam carriers look alike but if the machining of the hole was 1/2 thou out it cant run right it is being pushed to one side by the new one."

That's what I was informed by a few other people who own the k100's.
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chris-red
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PostPosted: 15:58 - 12 Oct 2015    Post subject: Reply with quote
TheSmiler wrote:
chris-red wrote:
Could you just replace the cam cap?


I was going to do this however apparently.

"cam carriers look alike but if the machining of the hole was 1/2 thou out it cant run right it is being pushed to one side by the new one."

That's what I was informed by a few other people who own the k100's.


I did wonder that, I think you use plastigage or something and can get them matched. Someone with more knowledge will hopefully be along soon. Laughing
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Aff
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PostPosted: 16:54 - 12 Oct 2015    Post subject: Reply with quote
I would just take the cap off and drill it out in a drill press, will be easy.

If you balls it up you can always helicoil it.
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Kris
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PostPosted: 20:44 - 12 Oct 2015    Post subject: Reply with quote
I had similar on a Bandit once, my cam cover had been over-tightened and cracked. I took it to my local dealer who passed me on to a small independent workshop. They welded it up and helicoiled it and it was fine. I presume the bolt is just for the rocker cover?

The guy is right btw, they are matched to the camshafts.
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TheSmiler
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PostPosted: 18:47 - 13 Oct 2015    Post subject: Reply with quote
Kris wrote:
I had similar on a Bandit once, my cam cover had been over-tightened and cracked. I took it to my local dealer who passed me on to a small independent workshop. They welded it up and helicoiled it and it was fine. I presume the bolt is just for the rocker cover?

The guy is right btw, they are matched to the camshafts.


The bolt is just for the rocker cover and crank case it attached to the fairing. Well anyway this doesn't really matter any-more as there is an update. Not true. New lesson learnt.

Be careful with cam covers and if you are unsure of doing it yourself get someone else to do it.

Anyway as I was saying update, don't you just love post Question Luckily after making a request on a face-book group specifically for k75/k100's I got a few people offer me parts. Most I already had so had to turn down. However did get one guy offer me a tail piece for postage. Bargain Exclamation

Here it is not pretty but it will do the job.

https://i.imgur.com/6kWZFxSl.jpg

Sorry I can't be bothered how to remove a few screws or remove the seat I followed the haynes manual, it's pretty simple. Nothing complicated and nothing caused problems. So here is the old tail piece; what is left of it.

https://i.imgur.com/UBuufdil.jpg

Anyway I also had another parcel delivered today I forgot to take a photo of it, I'm not really good at this show and tell. It happened to be my new tank, now before anyone says you should of just used the old one. It had fire damage so I didn't want to risk anything getting into the engine.

Anyway I opened the parcel and found an invoice saying 85 RT Tank. Now this made my jaw drop a bit. My bike is an RS so I was wondering if it would even fit. Turned out after removing the old one it did. Not that hard to remove extremely hard to bolt back up.

Now the price of this tank was a measely £45 from ebay with postage. Which included the lock now considering the lock set was going for about £80 on it's own on ebay. I don't think I've done that badly.

https://i.imgur.com/LIsFpmwl.jpg

As you can see it looks rather nice with the red tank. Well it does in my opinion.

I did have a problem with the old fuel tank though not removing it but attaching the fuel cable to the new tank. You see part of the spout had snapped off and was still in the pipe. I forgot to take a photo as I was kinda rushing at the time when doing this.

However I tried something that came into my head I got an old bolt and tightened it up inside, so the head was clean against the pipe. Luckily this is the type that goes in the crank case as well and didn't have a rubber.

https://i.ebayimg.com/00/s/OTYwWDEyODA=/$(KGrHqQOKiIE6(gRoByvBPzguqyBL!~~60_35.JPG

As you can see a similar image above. With that tight I used a pair of pliers with back and forth and with a few seconds it budged then split free.

https://i.imgur.com/1CPTouwl.jpg

Right now I thought this was all done for the day, however how wrong I was luckily a neighbour that I've been helping to build his bike and that let me use his garage to change the clutch on the k100 popped around. I explained to him about the snapped bolt and that I've sent off a few emails to get prices. He asked me to take it off and bring it around.

Using his pillar drill he drilled a small hole inside it then used a small screw extractor to wind it out took a few minutes of steady nerves.
https://i.imgur.com/0LJcY1bl.jpg

However from the image below you can see it worked a treat. We tried a bolt to see if it would go in and the thread wasn't damaged even though the head looks it.

https://i.imgur.com/5L4sdKyl.jpg

Right so now the bike looks like this below.

https://i.imgur.com/VKHLH4j.jpg

Now what's left to do or what's to do next. Well I'm leaving it for tonight early nights are not good when you are not working in a garage.

First things first, the cam cover will go back on tomorrow, I'll drain some fuel from the R1100RS and then attach a spare battery. After filling with oil I'll see if she starts, hopefully this will be nearing the end of this part of the project. That might be tomorrow not saying for certain.

On the other hand; I'm waiting for bolts to come to attach the headlight, plus a few other parts which should get it looking much nicer and actually roadworthy again. This all goes down to whether the engine is ok.
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TheSmiler
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PostPosted: 20:17 - 15 Oct 2015    Post subject: Reply with quote
Well I had a look at the bike and did a bit of extra work putting the cam cover back on and the rocker cover. Filled the bike with oil, now there are no more leaks. Headlight is on as well so that's good. Yes wrong beam pattern but it's not fixed or connected yet.

Seat has been priced up at £75 for cut to the shape I want, recovered and to be made comfier.

Did go and try start the bike the other day but found out that some of the wires are snipped on the brain box. Which means I'm most probably going have to re wire that. So close yet so far.

Bad image of both my bikes at the moment.

https://i.imgur.com/4kuMgFw.jpg
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TheSmiler
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PostPosted: 16:49 - 16 Oct 2015    Post subject: Reply with quote
Well I meant to update this yesterday with the image however I think I'll include it in this post. Here is an image of the "brain box" wiring. Looks like it's going to be a fun job.

https://i.imgur.com/Akuy1wh.jpg
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Doovy
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PostPosted: 16:56 - 16 Oct 2015    Post subject: Reply with quote
Bit of electrical tape, sorted Laughing
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Suntan Sid
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PostPosted: 18:30 - 16 Oct 2015    Post subject: Reply with quote
TheSmiler wrote:
Well I meant to update this yesterday with the image however I think I'll include it in this post. Here is an image of the "brain box" wiring. Looks like it's going to be a fun job.

https://i.imgur.com/Akuy1wh.jpg


If you haven't got this stuff yet, buy a soldering iron, solder, some shrink wrap tubing and start practising soldering on some scrap wire, until you're confident you can do it properly.
I couldn't solder for toffee until I practised lots of times, once you've mastered it thats an easy fix!
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TheSmiler
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PostPosted: 19:59 - 16 Oct 2015    Post subject: Reply with quote
Suntan Sid wrote:


If you haven't got this stuff yet, buy a soldering iron, solder, some shrink wrap tubing and start practising soldering on some scrap wire, until you're confident you can do it properly.
I couldn't solder for toffee until I practised lots of times, once you've mastered it thats an easy fix!


Haven't got any of the stuff to do the job for this I think I might just replace I've got some other wiring to do anyway for the modified tail light but that's for another part of the next project. Shhh!

IF I go for the replacement it will cost me £35 I believe and that way I can guarantee it works.
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Matt B
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PostPosted: 10:21 - 17 Oct 2015    Post subject: Reply with quote
Yes, but you wanted to to this for the experience, ride the learning curve, become a master K100 fettler and all that. So in the spirit of getting some experience, try the soldering method.

Irons are cheap, should find one with solder and a stand for a tenner, and shrink wrap is a couple of quid. Makes sense if you have other wiring to do as well.
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TheSmiler
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PostPosted: 13:05 - 03 Nov 2015    Post subject: Reply with quote
For anyone that is still interested, I've ran into problems with my other bike (R1100) clutch has gone. Replaced it with a brand new clutch and the clutch rod is now 5 mil too short. That's currently at another members so both bikes off the road.

Anyway I replaced the loom I couldn't be bothered with causing a potential fire hazard. And set about trying to get the bike started. I've had no luck as of recently. Everything was getting voltage however no cranking.

Now today I had a theory of pulling the plugs again after Marmalade suggested jump starting the starter motor whilst it was on the bike.

Tried jump starting however the bike still wouldn't turn over. Then pulled the plugs, now this below is not my image but I had basically the same.
https://www.skatemalaysia.com/planbmedia/plugbasah.jpg

Now Yes considering how the bike was found it hadn't really dawned on me to check them. Noob mistake I know.

However got the bike to crank over, just didn't start. I'm doing nights now so going get some sleep but will try the fuel down it's lug hole tomorrow to see if it fires.
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